Professional Documents
Culture Documents
CD
I~~~[fil
ENG
~@. .
ICOOL[ ~ [ICARB[ [
(J)
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols G) to
are designed as
thumb tabs to indicate the chapter's number and
content.
CD
General information
Specifications
Periodic inspection and adjustment
Engine
Cooling system
Carburetion
(J) Chassis
Electrical
Troubleshooting
()
@
@
@
IJ~~~[
OJ)
~
I~I
[0S]
~
@
~L@
a
1
~
~
~
~
1
e
~=sn
~L-
Illustrated symbols
to
are used to identify
the specifications appearing in the text.
Filling fluid
OJ) Lubricant
Special tool
@ Tightening
@ Wear limit, clearance
Engine speed
fl, V, A
Illustrated symbols @ to @ in the exploded diagram indicate grade of lubricant and location of
lubrication point.
@
@
@
@
@
Apply
Apply
Apply
Apply
Apply
Apply
gear oil
molybdenum disulfide oil
wheel bearing grease
lightweight lithium-soap base grease
molybdenum disulfide grease
locking agent (LOCTITE)
OT_O_R_C_Y_C_L_E_ID_E_N_T_IF_IC_A_T_I_O_N_I~~~I~I
_____________M
__
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number
is stamped
into the right side of the steering head.
CD
CD
1-1
IMPORTANT INFORMATION
II~ro I~I
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign material before removing and disassembling.
1-2
IMPORTANT INFORMATION
I~~ I~I
300-002
Do not use compressed air to spin the bearings dry. This causes damage to the bearing
surfaces.
300-003
1-3
______________________S_PE_C_IA_L_T_O_O_L_S_I~~~I~I
CIRCLIPS
1. All circlips should be inspected carefully
before reassembly. Always replace piston pin
clips after one use. Replace distorted circlips.
When installing a circlip G)' make sure that
the sharp-edged corner
is positioned
opposite to the thrust @ it receives. See the
sectional view.
CV
300-00 1
@ Shaft
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or improvised techniques.
The shape and part number used for the special
tool differ by country, so two types are provided.
Refer to the list provided to avoid errors when placing an order.
For
US, CON
Except for
PIN. 90890-00000
US, CDN
FOR TUNE UP
1. Valve adjusting tool
PIN. YM-08035- CD
PIN. 90890-01311 - CV
This tool is necessary for adjusting the valve
clearance.
2. Inductive tachometer
CD
CV
1-4
______________________SP_E_C_IA_L_T_O_O_L_S_II~~I~I
3. Inductive timing light
PI N. YM-33277-A- G)
PIN. 90890-03141- ~
This tool is necessary for checking ignition timing.
4. Compression gauge
PIN. YU -33223 -G)
PI N. 90890-03081 - ~
Adapter (M12)
PIN. YU-33223-3- @
PIN. 90890-04082 - @
These gauges are used to measure the engine
compression.
5. Fuel level gauge
PI N. YM-01312-A
PI N. 90890-01312
1-5
SPECIAL TOOLS
II~~ I~I
2. Rotor holder
PIN. YS-01880
PIN. 90890-01701
This tool is used to hold the rotor when removing or installing the rotor securing nut.
3. Rotor puller
PIN. YM-01080-A
PIN. 90890-01080
This tool is used to remove the rotor.
PIN. YM-91042-G)
PIN. 90890-04086 - ~
This tool is used to hold the clutch when removing or installing the clutch boss locknut.
PIN. YU-01135-A
PIN. 90890-01135
This tool is necessary to separate the crankcase.
6. Crankshaft protector
PIN. YM-01382
PIN. 90890-01382
This tool is used to remove the crankshaft.
1-6
SPECIAL TOOLS
II~~~ I~I
1-7
SPECIAL TOOLS
I~~ I~I
14. Adapter # 12
PIN. YM-01383
PIN. 90890-01383
This tool is used to install the crankshaft.
1-8
SPECIAL TOOLS
I~~~ I~I
2. Pocket tester
PIN . YU-03112
PIN. 90890-03112
This instrument is available for checking the electrical system.
1-10
~~~~~~~~~G_E_N_ER_A_L_S_PE_C_IF_IC_A_T_IO_N_S_ISPECI P1i
SPECIFICATIONS
GENERAL SPECIFICATIONS
XT225D/DC
Model
Model code number:
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
2,070 mm
800 mm
1,160 mm
810 mm
1,350 mm
285 mm
Basic weight:
With oil and full fuel tank
Engine:
Engine type
Cylinder arrangement
Displacement
Bore X Stroke
Compression ratio
Compression pressure standard
Starting system
Lubrication system:
Type
Engine oil type
(81.5
(31.5
(45.7
(31.9
(53.1
(11.2
in)
in)
in)
in)
in)
in)
Wet sump
Yamalube 4, SAE 20W40 type SE/SF motor oil or
SAE 10W30 type SE/SF motor oil
Oil capacity:
Periodic oil change
With oil filter replacement
Total amount
Air filter:
Type
2-1
GENERAL SPECIFICATIONS
Model
XT225D/DC
Fuel:
Type
8ST34/1 pc.
MIKUNI
Spark plug:
Type/Plug gap/Manufacturer
Clutch:
Type
Transmission:
Type
Operation
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Gear ratio:
Chassis:
Frame type
Caster angle
Trail
1st
2nd
3rd
4th
5th
6th
Diamond
26.5"
102 mm (4.0 in)
Tire:
Type
Size
Manufacture (type)
<Wear limit>
ISPEC I fU71
Front
With tube
2.75-21-4PR
8RIDGESTONE
(TW27)
YOKOHAMA
(E704)
<O.B mm (0.03 in
2-2
Rear
With tube
120/BO-1B-62P
8RIDGESTONE
(TW30)
YOKOHAMA
(E704)
<O.B mm (0.03 in
GENERAL SPECIFICATIONS
Model
1SPEC 1971
XT225D/DC
Front
Rear
125 kPa
(1.25 kg/cm2, 18 psi)
150 kPa
(1.5 kg/cm2, 21 psi)
150 kPa
(1 .5 kg/cm2, 21 psi)
150 kPa
(1.5 kg/cm2, 21 psi)
175 kPa
(1.75 kg/cm2, 25 psi)
175 kPa
(1.75 kg/cm2, 25 psi)
Maximum load
Up to 90 kg (198Ib) load
90 kg (198Ib)-Maximum load
High speed riding
Brake:
Front brake type
Front brake operation
Rear brake type
Rear brake operation
Suspension:
Front
Rear
Telescopic fork
Swingarm (newmonocross)
Shock absorber:
Front
Rear
Wheel travel:
Front
Rear
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
Headlight type
C.D.!.
A.C. magneto generator
YTX7L-BS
12V,6AH
Quartz bulb (halogen)
2-3
pc.)
pc.)
pc.)
pc.)
MAINTENANCE SPECIFICATIONS
ISPEC 195 71
MAINTENANCE SPECIFICATIONS
ENGINE
Model
XT225D/DC
Cylinder head:
<Warp limit>
<0.03 mm (0.0012 in
*Lines indicate straightedge measurement.
Cylinder:
Bore size
<Warp limit>
Measuring point (a)
Camshaft:
Drive method
Camshaft outside diameter
Shaft-to-cap clearance
Cam dimensions
Intake "A"
liB"
ue"
Exhaust "A"
liB"
lie"
<Camshaft runout limit>
Cam chain:
Cam chain type
Number of links
Cam chain adjustment method
DID25SH
104 Links
Automatic
2-4
MAINTENANCE SPECIFICATIONS
Model
Exhaust
"A" head diameter
"B" face width
"C" seat width
"D" margin thickness
ISPEC I y;f I
XT225DIDC
~~'
"A"
Outer spring
Valve spring:
Free length:
Intake
Exhaust
Set length (valve closed)
Intake
Exhaust
Direction of winding
(Top view)
<Tilt limit>:
Intake
Exhaust
Cou nterclockwise
Clockwise
c
<2.5"/1.6 mm (0.063 in
<2.5"/1.6 mm (0.063 in
2-5
<2.5"/1.6 mm (0.063 in
<2.5/1.6 mm (0.063 in
MAINTENANCE SPECIFICATIONS
Model
Piston:
Piston size "D"
Measuring point "H"
Oversize 2nd
Oversize 4th
XT225D/DC
~=-)~
I~
I_/TH
Piston off-set
Piston off-set direction
Piston-to-cylinder clearance
<Limit>
Piston ring:
Type:
Top ring
2nd ring
Dimensions (BXT):
Top ring
2nd ring
Oil ring
End gap (installed):
Top ring
2nd ring
Oil ring
Side clearance (installed):
Top ring
2nd ring
Crankshaft:
Crank width "A"
<Runout limit "C">
Big end side
Clearance "D"
Small end
<Free play limit "F">
Barrel
Taper
g=IB
',--_UB
I.
1
~JB
I.
~I
--F
ill
<0.8 mm (0.031 in
Balancer:
Drive method
ISPEC 11>'1 1
Gear
2-6
MAINTENANCE SPECIFICATIONS
XT225D/DC
Model
Clutch:
Friction plate:
Thickness
Quantity
<Wear limit>
Clutch plate:
Thickness
Quantity
<Warp limit>
Clutch spring:
Free length
Quantity
Minimum free length
Clutch housing:
Thrust clearance
Clutch release method
<Push rod bending limit>
Transmission:
<Main axle runout limit>
<Drive axle runout limit>
<0.08 mm (0.003 in
<0.08 mm (0.003 in
Shifter:
Type
Carburetor:
I.D. Mark
Main jet
Main air jet size
Jet needle
Needle jet
Pilot air jet size
Pilot jet
Pilot outlet
Bypass 1
Pilot screw
Valve seat size
Starter jet
(M.J.)
(MAJ.)
(J.N.)
(N.J.)
(PAJ. 1)
(PAJ.2)
(P.J.)
(P.O.)
(B.P.1)
(P.S.)
(V.S.)
(G.S.1)
(G.S.2)
(F.L.)
Float height
(F.H.)
ISPEC Iy;f I
XT225D (4BE1)
XT225DC (4BE2)
XT225D (4BE3)
4BE 10
#130
1.0
5DL27-1
0-1
#60
1.2
#40
0.85
0.8
Preset
2.0
#60
0.7
4BE 00
3RWOO
#122.5
0.9
5GN50-3/5
Q-O
#80
1.2
#42.5
--------
----
----
---
2-7
MAINTENANCE SPECIFICATIONS
Model
Lubrication system:
Oil filter:
Type
Oil pump:
Type
Tip clearance
Side clearace
Pressure checking location
XT2250/0C
2-8
ISPEC I~71
MAINTENANCE SPECIFICATIONS
1SPEC 11>71
TIGHTENING TORQUE
Part to be tightened
Cylinder head
Cylinder head and cylinder
Cylinder head
Cylinder head side cover 3
Cylinder head side cover 12
Plate
Spark plug
Cylinder
Balance weight gear
AC generator rotor
Valve clearance
Cam sprocket
Tensioner
Stopper guide 2
Oil pump assembly
Drain plug 1
Element cover
Element cover
Element cover
Carburetor joint 1
Carburetor
Air filter case fitting (front)
Air filter case fitting (rear)
Muffler mounting
Exhaust pipe fitting
Exhaust pipe protector
Tightening torque
Thread
Q'ty
size
Nm mekg ft elb
Part name
Remarks
Crossrecessed
hexagon bolt
Flange bolt
M6
0.7
5.1
Oil check
M8
22
2.2
17
Apply oil to
the washer
Bolt
Panhead screw
Bolt
Bolt
M8
M6
M6
M6
M12
M6
M14
M10
M6
M10
M6
M6
M6
M35
M6
M6
M6
M6
M5
M6
2
2
5
2
1
2
1
1
2
1
2
2
3
1
1
1
1
2
1
1
20
7
10
8
17.5
10
50
50
13.5
60
10
8
7
43
7
7
10
12
2
10
2.0
0.7
1.0
0.8
1.75
1.0
5.0
5.0
1.35
6.0
1.0
0.8
0.7
4.3
0.7
0.7
1.0
1.2
0.2
1.0
M6
10
1.0
7.2
M8
M6
M6
2
2
3
27
10
7
2.7
1.0
0.7
19
7.2
5.1
Bolt
Nut
Bolt
Nut
Bolt
Bolt
Bolt
Flat head screw
Panhead screw
Panhead screw
Bolt
Button head bolt
Hose clamp
Screw with
washer
Hexagon bolt
with washer
Flange bolt
Bolt
Bind head screw
14
5.1
7.2
5.8 Use lock washer
12.5
7.2
36 Use lock washer
36
10
43
7.2
5.8
5.1
31
5.1
5.1
7.2
8.7
1.4
7.2
uselock~
washer
Muffler protector
Screw
M6
0.7
5.1
Bolt
Panhead screw
Panhead screw
Panhead screw
M8
M6
M6
M6
1
7
2
2
20
7
7
7
2.0
0.7
0.7
0.7
14
5.1
5.1
5.1
Case 1 & 2
Panhead screw
M6
0.7
5.1
2-9
Use 10Ck_.o
washer
Tighten starter
motor together
ISPEC 11>71
MAINTENANCE SPECIFICATIONS
Part to be tightened
Crankcase cover 1
Crankcase cover 1
Clamp
Crankcase cover 2
Crankcase cover 3
Crankcase cover 3
Crankcase cover 3
Primary drive gear
Clutch spring
Clutch boss
Push lever assembly stopper
Push lever clearance adjusting
Drive sprocket
Shift pedal
Segment
Pulser coil
Neutral switch assembly
Charge coil
Stator coil
Tightening torque
Thread
Q'ty
size
Nm mokg ft lb
Part name
Remarks
Panhead screw
Panhead screw
Panhead screw
Panhead screw
Panhead screw
Panhead screw
Panhead screw
Nut
Screw with
washer
Nut
Screw
Nut
Bolt
Bolt
Screw
M6
M6
M6
M6
M6
M6
M6
M14
M5
6
2
1
2
5
3
2
1
4
7
7
7
7
7
7
7
50
6
0.7
0.7
0.7
0.7
0.7
0.7
0.7
5.0
0.6
5.1
5.1
5.1
5.1
5.1
5.1
5.1
36
4.3
M14
M8
M6
M6
M6
M6
1
1
1
2
1
1
70
12
8
10
10
12
7.0
1.2
0.8
1.0
1.0
1.2
51
8.7
5.8
7.2
7.2
8.7
Panhead screw
M6
M10
M5
2
1
2
7
20
4
0.7
2.0
0.4
5.1
14
2.9
-fl
-fl
M5
0.4
2.9
~a
Panhead screw
with washer
Panhead screw
with washer
2-10
Torques bolt
MAINTENANCE SPECIFICATIONS
ISPEC I!if I
Tightening sequence:
Cylinder head
Crankcase
Left-hand
Right-hand
~ Pressured feed
Lubrication chart:
Je
~ ~Ma;n",e
Drive axle
. . Splashed
Clutoh
-y
Gear
-y
Gear
-===-=-=======;,
"B--Shifter -
~~~J
---l
I
I
I
I Oil pump J
I
I
II
~l
~ Crank
Connecting rod
(big end)
.,.I1r
~ Connecting rod
-,
__ JI
-1
I
+( Balancer
~ Camshaft
I:---,J
Rocker arm
I::~
~,,~
1 Oil strainer I
I valve
Bypass I
1 Oil cleaner
Oil pan
2-11
MAINTENANCE SPECIFICATIONS
ISPEC IPf I
CHASSIS
XT2250/0C
Model
Steering system:
Bearing type
No'/Size of steel balls (upper)
Front suspension:
Front fork travel
Fork spring free length
<Minimum free length>
Spring rate
Stroke
(K1)
(K2)
(K1)
(K2)
Optional spring
Oil capacity
Oil level
Oil grade
Enclosed air pressure:
Standard
(Min.-Max.)
Rear suspension:
Shock absorber travel
Spring free length
Fitting length
Spring-rate
Stroke
Optional spring
Enclosed gas pressure
Swingarm:
<Free play limit>
Side clearance
<Free play limit>
Front wheel:
Type
Rim size
Rim material
<Rim runout limit>
Vertical
Lateral
(K1)
(K1)
72 mm (2.8 in)
189 mm (7.4 in)
174 mm (6.9 in)
61.5 N/mm (6.15 kg/mm, 344lb/in)
Zero-94 mm (Zero-3.7 in)
No
1,500 kPa (15 kg/cm2, 213 psi)
<1.0 mm (0.04 in
at swingarm end
Move swingarm end side to side.
0.4-0.7 mm (0.02-0.03 in)
at swingarm pivot
<1.0 mm (0.04 in
at swingarm pivot
Sporke wheel
1.6 X 21
Aluminum
<2.0 mm (0.08 in
<2.0 mm (0.08 in
2-12
MAINTENANCE SPECIFICATIONS
Model
Rearwheel:
Type
Rim size
Rim material
<Rim runout limit>
Vertical
Lateral
XT225D/DC
Sporke wheel
2.15 X 1B
Aluminum
<2.0 mm (O.OB in
<2.0 mm (O.OB in
Drive chain:
Type/Manufacturer
Number of links
Chain slack
42BV1/DAIDO
120
35-45 mm (1.3B-l.77 in)
Single
220 mm (B.7 in)
3.5 mm (0.14 in)
6.0 mm (0.24 in)
<O.B mm (0.03 in
11 mm (0.4 in)
34.93 mm (1.375 in)
DOT No.4 or DOT No.3
Leading, Trailing
110 mm (4.33 in)
< 111 mm (4.37 in
4.0 mm (0.16 in)
<2 mm (O.OB in
50.5 mm (1.99 in)
2-13
SPEC
P71
MAINTENANCE SPECIFICATIONS
1 SPEC 1
r;J
71
TIGHTENING TORQUE
Tightening torque
Part to be tightened
Front engine stay and frame
Front engine stay and engine
Engine stay 1 and frame
Engine stay 1 and engine
Engine and frame (rear, under)
Pivot shaft and nut
Relay arm and swingarm
Connecting rod and relay arm
Connecting rod and frame
Rear shock absorber and relay arm
Rear shock absorber and frame
Steering shaft and ring nut
Steering shaft and handle crown
Handle crown and inner tube
Handle crown and handlebar holder
Under bracket and inner tube
Handle crown and steering lock
Front wheel axle and nut
Caliper and front fork
Caliper and brake hose
Rear wheel axle and nut
Master cylinder and brake hose
Master cylinder and cap
Footrest (left) and frame
Footrest (right) and frame
Shift pedal and footrest bracket 1
Brake shaft and frame
Sidestand fitting bolt and nut
Sidestand fitting bolt and sidestand
Rear footrest (left) bracket and frame
Rear footrest (right) bracket and frame
Taillight fitting bolt and nut
Remarks
Thread size
M 8Xl.25
M 8Xl.25
M 8Xl.25
M 8Xl.25
M 8Xl.25
M12Xl.25
M12Xl.25
Ml0Xl.25
Ml0Xl.25
Ml0X1.25
M10X1.25
M25X1.0
M14X1.25
M 8X1.25
M 8X1.25
M 8X1.25
M 6X1.0
M14X1.5
M10X1.25
M10X1.25
M14X1.5
M10X1.25
M 4XO.7
M10X1.25
M10X1.25
M 8X1.25
M14X1.5
M10X1.25
M10X1.25
M 8X1.25
M 8X1.25
M 6X1.0
Nm
mokg
ft lb
33
33
38
33
33
80
55
32
32
32
32
5.5
70
23
15
20
7
85
35
27
85
27
1.5
32
42
20
30
40
40
28
28
5.5
3.3
3.3
3.8
3.3
3.3
8.0
5.5
3.2
3.2
3.2
3.2
0.55
7.0
2.3
1.5
2.0
0.7
8.5
3.5
2.7
8.5
2.7
0.15
3.2
4.2
2.0
3.0
4.0
4.0
2.8
2.8
0.55
24
24
27
24
24
58
40
23
23
23
23
4
50
17
11
14
5.1
61
25
19
61
19
1.1
23
30
14
22
29
29
20
20
4
Refer to NOTE
NOTE: ___________________________________________________________
1. First, tighten the ring nut approximately 38 Nm (3.8 m kg, 27 ft. Ib) by using the torque wrench,
then loosen the ring nut one turn.
2. Retighten the ring nut to specification.
2-14
~~~~~~~_M_A_IN_T_EN_A_N_C_E_S_PE_C_IF_IC_A_T_IO_N_S_ISPECI~' I
ELECTRICAL
XT225D/DC
Model
Voltage:
12V
Ignition system:
Ignition timing (B.TD.C.)
Advanced timing (B.TD.C.)
Advancer type
9 at 1,400 r/min
31/6,000 r/min
Electrical type
;;
1----.
30
OJ
20
II
c
0
:-ec
I~,OOO
29.5
27/4,250
--
,I;V
a::i
E
..;:::;
---
- -
~f-'-/
U
c:i
c
.-
31/6,000
9 11,400
OJ
10
/'/
~I
$11'/2,100
.- '/
2
10
12
CD.I.:
Unit model/Manufacturer
Pickup coil resistance (color)
Charging coil resistance (color)
4BEIYAMAHA
656-984Q at 20C (68F) (Red-White)
584-876Q at 20C (68F) (Brown-Green)
20-30Q at 20C (68F) (Yellow-Black)
Ignition coil:
Model/Manufacturer
Primary coil resistance
Secondary coil resistance
Minimum spark gap
2JNIYAMAHA
0.56-0.84Q at 20C (68F)
5.68-8.52kQ at 20'C (68F)
6.0 mm (0.24 in)
Resin type
10kQ at 20C (68F)
Charging system:
Type
2-15
MAINTENANCE SPECIFICATIONS
ISPEC I fJf I
XT2250/0C
Model
A.C. generator:
Model/Manufacturer
Charging output
2YGIYAMAHA
14V, lOA at 5,000 r/min
20
<t:
.....
16
~:::J
12
...-
.....
:::J
c.
.....
/v
:::J
V
0
10
12
SH569A-12/SHINOENGEN
Semi conductor - Short circuit type
14.3-15.3V
12A
Battery:
Specific gravity
1.320
Starter motor:
Model/Manufacturer
Output
Brush overall length
<Limit>
Commutator diameter
<Limit>
Mica undercut (depth)
3RW11Y AMAH A
0.4kW
10.0 mm (0.39 in)
<3.5 mm (0.14 in
22.0 mm (0.87 in)
<21.0 mm (0.83 in
1.5 mm (0.06 in)
2-16
MAINTENANCE SPECIFICATIONS
Model
XT225D/DC.
Starter switch:
Model/Manufacturer
Amperage rating
MS5D - 191/HITACHI
100A
Horn:
Type
Quantity
Model/Manufacturer
Maximum amperage
Plane type
1 pc.
GF-121NIKKO
1.5A
Flasher relay:
Type
Model/Manufacturer
Self cancelling device
Flasher frequency
Wattage
Circuit breaker:
Type
Amperage for individual circuitXQuantity:
Main
Reserve
Fuse
15A/1 pc.
15A/1 pc.
2-17
1 SPEC 1
P71
I SPEC I"G Q I
. r I .
A
(Nut)
B
(Bolt)
General torque
specifications
Nm
m-kg
10mm
6mm
0.6
4.3
12mm
8mm
15
1.5
11
14mm
10mm
30
3.0
22
17mm
12mm
55
5.5
40
19mm
14mm
85
8.5
61
22mm
16mm
130
13.0
94
DEFINITION OF UNITS
Unit
Definition
Read
3
Measure
mm
cm
millimeter
centimeter
10- meter
10-2 meter
Length
Length
kg
kilogram
103 gram
Weight
Newton
1 kg X m/sec2
Force
Nm
m-kg
Newton meter
Meter kilogram
NXm
m X kg
Torque
Torque
Pa
N/mm
Pascal
Newton per millimeter
N/m 2
N/mm
Pressure
Spring rate
L
cm 3
Liter
Cubic centimeter
Volume or capacity
r/min
Engine speed
2-18
ft-Ib
~~
Piston pin
-IG]
-IG]
-IG]
-IG]
-IG]
-IG]
-IG]
-I~
-Ie
-IG]
-IG]
-I~
~~
-IG]
-IG]
-I~
-I~
-IG]
-IG]
-IG]
Push rod
2-19
~~~~L_U_B_R_IC_A_T_IO_N~PO~IN_T_S_A_N_D_L_U_B_R_IC_A_N_T_T_Y_P_E~ISPECI ~'I
CHASSIS
Lubricant type
...--::I~
...--::I~
...--::I~
...--::I~
~~
Collar (swingarm)
~~~
~~~
~-"i-~
~~~
~Il.L~
~-"iL~
~~~
~~
...--::I~~
...--::I~~
~~.~
...--::I~~
...--::I~~
~-"iL~
...--::I~~
2-20
----
LUBRICATION DIAGRAM
LUBRICATION DIAGRAM
CD Oil pump
2-21
1 SPEC 1
rtf
LUBRICATION DIAGRAM
CD
@
@
(J)
@
(jJ)
@
Oil pump
Oil cleaner assembly
Element cover
O-ring
Bolt
O-ring
Gear cover
Pump cover gasket
Oil strainer
Compression spring
O-ring
Drain plug
2-22
ISPEC I fJf I
~~~~~~~~~~~_CA_B_L_E_RO_U_T_IN_G_ISPECI ~'I
CABLE ROUTING
CD Clutch cable
Master cylinder
Front brake hose
Throttle cable
Band
Throttle cable
(j) Band
(jJ)
@
@
(jJl
@
@
@
Clutch cable
Handlebar switch lead (left)
Clutch switch lead
Speedometer lead
Flasher light lead (left)
Speedometer cable
Wireharness
Flasher light lead (right)
Main switch lead
Pilot box lead
@ Brake hose
(j]) Front brake switch lead
IAl
~ Procedure
1. Connect the wires to the
flasher light (right), pilot box,
front brake switch, handlebar
switch (right) and main switch.
2. Connect the wires to the
switch,
handlebar
clutch
switch (left), meters and
flasher light (left), crossing the
wires over the wires used in
step 1.
3. After the wiring is completed,
put the coupler underneath
the meter and pilot box.
4. Clamp the wires at the point
where taping will stop near
the wireharness.
(Locate the protection taped
portion above the headlight
rim).
I~
5
2-23
CABLE ROUTING
CD
@)
(j)
@
(j])
@
@
(j})
@
@
@
@
@
Horn lead
Cable guide
Starter cable
Ignition coil
Band
Clamp
Fuel pipe
Air vent pipe
Overflow pipe
Clamp
Air cleaner
Drain pipe
Sidestand switch lead
Sidestand switch
Crankcase breather hose
Flywheel magneto lead
Seat pillar (left)
Clamp
Overflow pipe
@
@
@
@
@
>
@
@
[AJ
lID
ISPEC IPf
W To engine
W To start motor
*
@
2-24
**For USA-California
~~~~~~~~~~~C_A_BL_E_R_O_UT_IN_G~ISPECI~' I
CD
ell
Band
Flasher relay
Starting circuit cut-off relay
COl unit
COl unit lead
White tape
(J) Carburetor
Canister hose
(for California only)
Band
Ignition coil
(jJ) Wireharness
@ Horn lead
@ Band (for California only)
(jJJ Canister (for California only)
Band
@ Clamp
@
@
@
@
@
@
@
@
lID
Clamp
Rear brake switch lead
Rear brake switch
Guide
Carburetor overflow pipe
Air vent pipe
Fuse
Battery
Battery lead (+)
Battery lead (-)
Starter relay
Taillight lead
Flasher light lead
Wireharness
Do not band.
Tighten the engine stay and the
canister hose (for California only).
2-25
[Q
CABLE ROUTING
CD Rectifier/regulator
Band
Clamp
Rear flasher light lead (right)
Clamp
Taillight lead
ISPEC I'? f I
Band
Neutral relay
2-26
ISPEC I fJ f I
CD
Canister ass'y
Cap ass'y
Fuel tank camp.
@ O-ring
Roll over valve ass'y
Fuel cock ass'y
(J) Hose (Canister-carburetor)
Over flow pipe
Hose
@ Hose
(jJ) Clip
@Clip
@ Hose (canister-roll over valve)
2-27
INTRODUCTION/
MAINTENANCE INTERVALS CHART
INSP
ADJ
ODOMETER READING
1,000 km or
1 month
(600 mil
** 1
6,000 km or
7 months
(3,800 mil
**2
11,000 km or
13 months
(6,900 mil
16,000 km or
19 months
(10,000 mil
21,000 km or
25 months
(13,100 mil
NO.
ITEM
REMARKS
1."
Valve clearance
2. '
Spark plug
Replace
Replace
3. '
Crankcase
breather system
4. '
Fuel line
5. *
Exhaust system
6. "
Idle speed
7. *
Evaporative
emission control
system "
..
It IS recommended that these Items be serviced by a Yamaha dealer or other qualified mechanic.
,. California type only.
NOTE:
For farther odometer reading, repeat the above maintenance at the period established; **1: Every 5,000
km (3,100 mil and **2: Every 10,000 km (6,200 mil intervals.
3-1
INSP
ADJ
ITEM
REMARKS
TYPE
'1) Yamalube 4
(20W40) or SAE
20W40 type "SE"
motor oil
*2) Yamalube 4
(10W30) or SAE
10W30 type "SE"
motor oil
1.
Engine oil
Warm-up engine
before draining
2.
3. '
Air filter
Brake system
5. * Clutch
6.
Drive chain
7.*
Control and
meter calbe
8.'
9.
Brake / Clutch
lever pivot shaft
10.
4. *
ODOMETER READINGS
* '1
*' 2
1,000 km or 6,000 km or 11,000 km or 16,000 km or 21,000 km or
19 months 25 months
1 month
7 months
13 months
(600 mil
(3,800 mil
(6,900 mil
(10,000 mil
13,100 mil
Lubricate.
Apply chain lube
lightly.
Sidestand
switch
Medium weight
wheel bearing
grease.
3-2
IANOSJP I~ I
I
---------------------------------------------------MAINTENANCE INTERVALS CHART
~.
NOTE : ___________________________________________________
For farther odometer reading, repeat the above maintenance at the period established; **1: Every 5,000
km (3,100 mil and **2: Every 10,000 km (6,200 mil intervals.
3-3
__IN_T_E_N_A_N_C_E_I_liANOSJPI~I
LUBRICATION
INTERVALS _
_~. _
_________________P_E_R_IO_D_I_C_M_A
PERIODIC MAINTENACE/LUBRICATION INTERVALS (For CON)
EVERY
ITEM
REMARKS
Valve(s)*
Spark plug
Air filter
Carburetor*
Fuel line*
Engine oil
Clean.
Clean.
Front Brake*
BREAK-IN
1,000
(600)
6,000
(4,000)
or6
months
12,000
(8,000)
or 12
months
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Rear Brake
Clutch
Wheels*
Wheel bearings*
Steering bearings*
Front fork*
Drive chain
Fittings / Fasteners*
Sidestand*
Sidestand switch*
*.
It IS recommended that these Items be serviced by a Yamaha dealer.
**. Medium weight wheel bearing grease.
*** : Lithium soap base greaSE.
3-4
0
0
0
0
0
0
0
0
0
0
0
__M_A_IN_T_E_N_A_N_C_E_I_IIANOSJPI~I
_________________P_ER_I_O_D_IC
LUBRICATION INTERVALS.
. ~ .
NOTE: ___________________________________________________
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add the fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
3-5
IANOSJP I~ I
I
-------------------------------------------------------~.
1. Remove:
-Side cover (left)
CD
NOTE: _________________________
When removing the side cover (left), remove the
bolt (with claw washer) 0. Then pull the front
and rear portion of the side cover outward to remove the projection Q) from the grommet.
2. Remove:
-Side cover (right)
CD
NOTE: _________________________
When removing the side cover (right), remove the
bolt 0. Then pull the front portion of the side
cover outward to rerTivve the projection Q) from
the grommet. Then pull the rear portion of the
side cover outward to remove the receptacle @
from the lobe.
3-6
------------------------------------------------------ I
SEAT, FUEL TANK AND COVER
IANOSJP
I~
.I
~
3. Remove:
-Seat CD
4. Remove:
-Air scoop (left) CD
-Air scoop (right)
CV
NOTE: _________________________
When removing the air scoop (left), remove the
bolt @ . The bolt @ is linked with the right air
scoop stay, so take care not to drop the fixing
part and nut of the right air scoop stay when
loosening. Then pull the rear portion of the airscoops outward to remove the projection @
from the grommet. Then pull the rear portion @
of the air scoop forward to remove the air scoop
from the fuel tank.
IAl
IANOSJP I......
~I
I
-----------------------------------------------------SEAT, FUEL TANK AND COVER
6. Disconnect:
- Fuel hose CD
NOTE: __________________________
Place a rug on the engine to absorb a spilt fuel.
A WARNING
Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.
7. Remove:
- Fuel tank
CD
8. Disconnect:
- Roll over valve hose (for California only)
INSTALLATION
Reverse the "REMOVAL" procedure. Note the
following points.
1. Install:
-Fuel tank
-Air scoops
Bolt (seat):
7 Nm (0.7 m.kg, 5.1 ft.lb)
Bolt (side cover):
7 Nm (0.7 m.kg, 5.1 ftlb)
3-8
__________________________C_O_W_Ll_N_G_~g~I~1
COWLING
REMOVAL
1. Remove:
-Cowling CD
NOTE: _ _ _ _ _ _ _ _ _ _ _ ___
CD,
INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Install:
-Cowling
Bolts (cowling):
7 Nm (0.7 m.kg, 5.1 ftlb)
3-9
IANOSJP I~ I
I
-----------------------------------------------------~-
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Remove :
- Side covers
-Seat
-Air scoops
-Fuel tank
Refer to the "SEAT, FUEL TANK AND
COVER" section .
2. Remove:
-Tappet cover
-Tappet cover
CD
ClJ
(intake)
(exhaust)
3. Remove:
-Plug CD (with O-ring)
-Plug
(with O-ring)
ClJ
4. Align:
- "T" mark on the rotor
With the stationary pointer on the crankcase
cover.
*****************************************
3-10
INSP
ADJ
CD
CD
*****************************************
4. Check:
-Valve clearance
Measure the valve clearance by using a feeler
gauge
Out of specification ~ Adjust.
CD.
Adjustment steps:
CD .
IANOSJP I~ I
I
-----------------------------------------------------VALVE CLEARANCE ADJUSTMENT
"
~~
~.
Locknut:
13.5 Nm (1.35 m.kg, 10 ftlb)
6. Install:
Reverse the removal procedure.
-Plugs
-Tappet cover (intake)
- Tappet cover (exhaust)
Bolts (tappet cover):
10 Nm (1.0 m.kg, 7.2 ft.lb)
NOTE: _________________________
CD
CD
CD.
!AI
lID
Intake
Exhaust
7. Install:
-Fuel tank
-Air scoops
-Seat
-Side covers
Refer to the "SEAT, FUEL TANK AND
COVER" section.
3-12
INSP
ADJ
4. Adjust:
-Engine idling speed
*****************************************
Adjustment steps:
Turn in the pilot screw CD until it is lightly
seated.
Turn out the pilot screw for the specified number of turns.
Pilot screw (For CDN):
2 turns out
(For US, California)
Unadjustable from regulations.
Turn the throttle stop screw ~ in or out until
specified idling speed is obtained.
Turn in-->Idling speed becomes higher.
Turn out-->Idling speed becomes lower.
*****************************************
3-13
IANOSJP I~ I
I
-----------------------------------------------------THROTTLE CABLE FREE PLAY ADJUSTMENT
~.
5. Remove:
-Inductive tachometer
6. Adjust:
-Throttle cable free play
Refer to the "THROTTLE CABLE FREE
PLAY ADJUSTMENT" section.
I~
Free play:
3-5 mm {D.12-D.20 in}
1. Check:
-Throttle cable free play
Out of specification ---. Adjust.
Throttle cable free play:
2. Remove:
- Side covers
-Seat
-Air scoops
-Fuel tank
Refer to the "SEAT, FUEL TANK AND
COVER" section.
3. Adjust:
-Throttle cable free play
3-14
INSP
ADJ
*****************************************
Adjustment steps:
First step:
CD
Turning in
Turning out
CD
Turning in
Turning out
(2).
A WARNING
After adjusting the free play, turn the handlebar to right and left, and make sure that
the engine idling does not run faster.
3-15
G)
2. Remove:
-Spark plug
3. Inspect:
-Spark plug type
Incorrect --> Replace .
DR8EA (N.G.K.L
X24ESR-U (NIPPONDENSo)
4. Inspect:
- Electrode G)
Wear / Damage--> Replace.
-Insulator ~
Abnormal color--> Replace.
Normal color is a medium-to-light tan color.
5. Clean the spark plug with a spark plug cleaner or wire brush.
6. Measure:
-Plug gap
Use a wire gauge or feeler gauge.
Out of specification --> Regap.
3-16
Spark plug:
17.5 Nm (1.75 m.kg, 12.5 ftlb)
NOTE: _________________________
- Before installing a spark plug, clean the gasket
surface and plug surface.
-If a torque wrench is not available when you are
installing a spark plug, a good estimate of the
correct torque is 114 to 112 turns part finger
tight. Have the spark plug torque to the correct
value as soon as possible with a torque wrench.
8. Connect:
- Spark plug cap
1. Start the engine and let it warm up for several minutes, then stop the engine.
2. Attach:
-Inductive tachometer
-Timing light
to spark plug lead.
Inductive tachometer:
PIN. YU-08036-A
PIN. 90890-03113
Timing light:
PIN. YM-332n-A
PIN. 90890-03141
3-17
INSP
ADJ
3. Check:
-Ignition timing
*****************************************
Checking steps:
Remove the plug G).
Start the engine and let it run at the specified
speed.
/"'
<
.\
.V ):.
Engine speed:
1,400 r/min
1111111 ~1;
________
NOTE: _________________________
Ignition timing is not adjustable.
*****************************************
4. Install:
-Plug
5. Detach:
-Timing light
-Inductive tachometer
3-18
1. Check:
-Valve clearance
Out of specification -> Adjust.
Refer to the "VALVE CLEARANCE ADJUSTMENT" section.
6. Attach:
-Compression gauge
- Adapter CZJ
CD
Compression gauge:
PIN. YU-33223
PIN. 90890-03081
Adapter:
PIN. YU-33223-3
PIN. 90890-04082
7. Check:
-Compression pressure
*****************************************
Checking steps:
Crank over the engine with the electric starter
(be sure the battery is fully charged) with the
throttle wide-open until the compression reading on the gauge stabilizes.
A WARNING
When cranking the engine, ground the spark
plug lead to prevent sparking .
3-19
INSP
ADJ
Diagnosis
Worn or damaged
pistons
Defective ring(sl.
valves, cylinder head
gasket or piston is
possible.
Above maximum
level
*****************************************
8. Install:
-Spark plug
I\.
~~
Spark plug:
17.5 Nm (1.75 m.kg, 12.5 ft.lb)
3-20
_
ENGINE
OIL _
LEVEL_
INSPECTION.
-----'--_
__
__
__ 1
iANOSJP
~ .I
I. ~
>
I II.I I.I Ni:.:.
-Do not add any chemical additives. Engine
oil also lubricates the clutch and additives
could cause clutch slippage.
- Do not allow foreign material to enter the
crankcase.
CD.
NOTE: __________________________
-- - - -(2)
NOTE: __________________________
Wait a few minutes until level settles before inspecting .
30
40
50
10
.{p
60F
15C
YAMALUBE-4
(20W401or
SAE20W40
SE / SF
YAMALUBE-4
(10W301or
SAE10W30
SE / SF
3-21
Oil quantity:
Periodic oil change
1.0 L (0.88 Imp qt, 1.06 US qt)
With oil filter replacement
1.1 L (0.97 Imp qt, 1.16 US qt)
Total amount
1.3 L (1.14 Imp qt, 1.37 US qt)
;:;1111,.1:;'; ________
-Do not add any chemical additives. Engine
oil also lubricates the clutch and additives
could cause clutch slippage.
- Do not allow foreign material to enter the
crankcase.
CD
3-22
CD
5. Drain:
-Engine oil
6. Remove:
- Bolt
(oil filter cover-lower)
CD
NOTE: ________________________
__
The oil filter cover is secured by three screws. The
lower one should be removed so that the filter
cavity will drain.
7. Inspect:
-O-ring (drain plug)
Damage-t Replace.
8. Clean:
-Oil strainer
Clean it with solvent.
Clog/ Damage-+ Replace.
9. Install:
- Bolt (oil filter cover-lower)
-Drain plug
Before reinstalling the drain plug, do not forget to fit the O-ring, compression spring and
oil strainer.
3-23
I~g~ IN I
10. Fill :
-Crankcase
Periodic oil change:
1.0 L (0.88 Imp qt, 1.0G US qt)
Recommended engine oil:
At 5C (40F) or higher:
YAMALUBE-4 (20W40) or
SAE 20W40 type SElF motor oil
At 15C (GOF) or lower
YAMALUBE-4 (10W30) or
SAE 10W30 type SElF motor oil
. II.IIIII~ I
________
13. Install:
- Engine guard
CD
3-24
CD (oil
tank)
NOTE: __________________________
When removing the drain plug tl), the compression spring @ , oil strainer @ and O-ring will
fall off. Take care not to lose these parts.
5. Drain:
-Engine oil
6. Remove:
- Bolt
(oil filter cover-lower)
CD
NOTE: _________________________
The oil filter cover is secured by three screws. The
lower one should be removed so that the filter
cavity will drain.
7. Remove:
Oil filter cover
-Oil filter tl)
-O-ring @
3-25
CD
_OIL
_
_ _ _ IIANOSJP
ENGINE
REPLACEMENT.
_ _____
I~
. ~ .I
8. Inspect:
-O-ring G)
Damage-4 Replace.
9. Clean:
-Oil filter
Clean it with solvent
Clog / Damage-4 Replace.
ClJ
10. Install:
- Oil filter
G)
11111,11;,1 ________
Install the oil filter as shown.
-Oil filter cover
- Drain plug (crankcase)
Before reinstalling the drain plug. do not forget to fit the O-ring. compression spring and
oil strainer.
.
.
~~jl~1
~
12. Install:
-Oil filler cap
13. Inspect:
-Oil level
Refer to the "ENGINE OIL LEVEL INSPECTION" section.
-Oil pressure
Refer to the "OIL PRESSURE INSPECTION" section.
-Oil leaks
14. Install:
- Engine guard
Bolt (engine guard):
7 Nm (0.7 m.kg, 5.1 ftlb)
CD
1. ,. .1;; ________
If no oil comes out after a lapse of one
minute, turn off the engine immediately so
it will not seize.
4. Tighten:
-Oil check bolt
Oil check bolt:
7 Nm (0.7 m.kg, 5.1 ft.lb)
YB2AFOOO
~~ .
I
'" ........ '" "
CLUTCH ADJUSTMENT
1. Check:
-Clutch cable free play
Out of specification---Adjust .
_ _- --
....
--
Free play:
10-15 mm (0.4-0.6 in)
at clutch lever end
c--
3-27
INSP
ADJ
*****************************************
Adjustment steps:
First step:
Make sure that the adjuster
are fully tighened.
Tighten
the locknut Q).
NOTE:
________________________
_
If the free play is incorrect, adjust the clutch cable free play with the adjuster (part of clutch lever
holder).
Second step:
CD
(2).
*****************************************
CD
1. Remove:
-Side cover (left)
Refer to the " SEAT, FUEL TANK AND
COVER" section.
- Air filter case cover
CD
3-28
INSP
ADJ
CD
;11,11111;;1________
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid wear and possi ble engine damage. Additionally, operation
without the filter element will affect carburetor tuning with subsequent poor performance and possible engine overheating.
3. Inspect:
Air filter element
Damage~ Replace.
CD
4. Clean:
Air filter element
Clean it with solvent.
NOTE: _________________________
After cleaning, remove the remaining solvent by
squeezing the element.
Do not twist the filter element when squeezing the filter element.
"AWARNING
Never use low flash point solvents such as
gasoline to clean the air filter element. Such
solvent may lead to a fire or explosion.
3-29
IANOSJP I~ I
I
-----------------------------------------------------~.
6. Install:
- Air filter element
NOTE: __________________________
CD
7. Install:
- Air filter case cover
-Side cover (left)
Bolt (side cover):
7 Nm (0.7 m.kg, 5.1 ftlb)
CD,
Bolt
(carburetor joint):
3. Install:
-Seat
-Side cover
Bolts (seat and side cover):
7 Nm (0.7 m.kg, 5.1 ftlb)
3-30
I~g~ I~
rzr.I
2. Inspect:
- Fuel hose CD
Crack/ Damage-4 Replace.
3. Install:
- Side cover (left)
3-31
I~g~ I~ I
. ~ .
CD
CANISTER INSPECTION
(CALIFORNIA ONLY)
1. Inspect:
-Hose connection
Poor condition --> Correct.
-Hoses
- Canister
Cracks/ Oamage--> Replace.
Clogs--> Clean.
CD
3-32
INSP
ADJ
Inl
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check:
Brake lever free play
Out of specification -4 Adjust.
I~
Free play:
2-5 mm (0.08-0.20 in)
2. Adjust:
Brake lever free play
*****************************************
Adjustment steps:
Loosen the locknut
Turn the adjuster ~ in or out until the specified free play is obtained.
CD.
A WARNING
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. This air must be removed by bleeding the brake system before the motorcycle
is operated. Air in the system will cause
greatly diminished braking capability and
can result in loss of control and an accident.
Inspect and bleed the system if necessary.
3-33
D_L_E_V_EL_IN_S_P_E_C_TI_O_N_I_IIANOSJP I
_ _ _ _F_R_O_N_T_B_R_A_K_E_F_L_U_I
FRONT BRAKE PAD INSPECTION.
.
f i I.
2. Inspect:
~\
~OWER._~
l,--------,
A WARNING
- Use only the designated quality brake fluid:
otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
- Refill with the same type of brake fluid;
mixing fluids may result in a harmful chemical reaction and lead to poor performance.
- Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
I~ Wear limit:
rAl
3-34
_____________
A_IR_B_LE_E_D_IN_G_I
~g~ If i I
A WARNING
Bleed the brake system if:
-The system has been disassembled.
-A brake hose has been loosened or
removed.
-The brake fluid is very low.
-The brake operation is faulty.
A dangerous loss of braking performance
may occur if the brake system is not properly
bled.
1. Bleed:
- Brake system
*****************************************
CD
,
,
Bleed screw:
6 Nm (0.6 m.kg, 4.3 ftlb)
i. Repeat steps (e) to (h) until all of the air bubbles have been removed from the system.
3-35
.I
IANOSJP I ~~I
----------------------------------------------NOTE: __________________________
A WARNING
Check the operation of the brake after bleeding brake system.
*****************************************
YB2A3004
A WARNING
After adjusting the brake pedal height or free
play, brake light switch should be adjusted .
1. Check:
Brake pedal height
Out of specification -+ Adjust.
Adjustment steps:
Loosen the locknut CD .
Turn the adjuster (2) in or out until the specified pedal height is obtained .
3-36
Turning
in ~ Pedal
Turning
out ~ Pedal
height is increased .
height is decreased.
A WARNING
After adjusting the brake pedal height.
just the brake pedal free play.
ad~
*****************************************
3. Check:
Brake pedal free play
Out of specification -> Adjust.
NOTE: _________________________
Before adjusting the brake pedal free play, the
brake pedal height should be adjusted.
4. Adjust:
Brake pedal free play
*****************************************
CD
*****************************************
CD
3-37
INSP
ADJ
1. Check:
Brake light operating timing
Incorrect--+ Adjust.
2. Adjust:
Brake light operating timing
***** *** ** ********** **** ***** ******** *** *
Adjustment steps:
Hold the switch body
with your hand so that
it does not rotate and turn the adjusting nut (2).
CD
******** ** ********************** ** * ** * * * *
. , ; -----------------------
Too little of chain slack will overload the engine and other vital parts; keep the slack within the specified limits.
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
3-38
INSP
ADJ
2. Check:
Drive chain slack
Out of specification -+ Adjust.
3. Adjust:
Drive chain slack
************** * **** ***** ********** * * *****
Adjustment steps:
Remove the cotter pin
and loosen the axle
nut (2).
Turn the chain pullers
clockwise or counterclockwise until the specified slack is obtained.
CD
NOTE: _________________________
Turn each chain puller exactly the same amount
to maintain correct axle alignment. (There are
marks on each chain puller. Use them to check
for proper alignment.)
Tighten the axle nut to specification, while
pushing up or down on the chain to zero slack.
Axle nut:
85 Nm (8.5 m-kg, 61 ft-Ib)
****************************** * **********
3-39
INSP
ADJ
CD
Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned
with the cotter pin hole, align groove with
the hole by tightening up on the axle nut.
A WARNING
Always use a new cotter pin.
YB2A4025
CD.
343-003
Recommended lubricant:
SAE 30 - SOW Motor Oil or
chain lubricants suitable for
"O-ring" chains.
3-40
INSP
ADJ
YB3AlOOO
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
3. Check:
Steering assembly bearings
Grasp the bottom of the forks and gently
rock the fork assembly back and forth.
Looseness ~ Adjust steering head.
4. Adjust:
Steering head
*****************************************
Adjustment steps:
Remove the side cover, seat, air scoops and fuel
tank.
Remove the bolt
(steering shaft) and loosen the bolt (l) (handlebar crown).
Tighten the ring nut using the ring nut wrench.
NOTE: _________________________
CD
3-41
.
.
l~g~I~1
~-
A WARNING
Avoid over-tightening.
5. Install:
-Fuel tank
6. Tighten:
- Bolt (fuel. tank)
-Air scoops
-Seat
-Side cover
Bolt (fuel tank, air scoops, seat
and sidecovers):
7 Nm (0.7 m.kg, 5.1 ftlb)
3-42
I~g~ I~ I
_
_~_ .
YB2A 1001
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
CZ>
3. Check:
-Inner tube
Scratch/ Damage~ Replace.
-Oil seal
Excessive oil leakage~Replace.
4. Hold the motorcycle on upright position and
apply the front brake.
5. Check:
-Operation
Pump the front fork up and down for several
times.
Unsmooth operation ~ Repair.
Refer to the "FRONT FORK" section in the
CHAPTER 6.
6. Install:
-Fork boots
-Sand
Refer to the "FRONT FORK-INSTALLATION" section in the CHAPTEA 6.
EB1Al003
A WARNING
-Always adjust each fork to the same setting. Uneven adjustment can cause poor
handling and loss of stability.
-Securely support the motorcycle so there
is no danger of it falling over.
3-43
_ ___________________
FRONT FORK ADJUSTMENT.IIANOSJPI.a1
.
.
~_
NOTE:
When checking and adjusting the air pressure,
there should be no weight on the front end of the
motorcycle.
2. Remove:
- Air valve caps
CD
3. Adjust:
-Air pressure
*****************************************
Adjustment steps:
-Check the air pressure with an air pressure
gauge.
Stiffer-+lncrease the air pressure.
(Use an air pump or pressurized
air supply.)
Softer-+ Decrease the air pressure.
(Release the air by pushing the
valve.)
3-44
IANOSJP I~ I
I
---------------------------------------------------------REAR SHOCK ABSORBER ADJUSTMENT
~_
A WARNING
The difference between the left and right
tubes should be 10 kPa (0.1 kg/ cm 3 , 1.4 psi)
or less.
*****************************************
4. Install:
- Air valve caps
Y82A2002
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Adjust:
-Spring preload
-Damping
3-45
IANOSJP I ~ I
I
-----------------------------------------------------~-
Adjustment steps:
Spring preload
Loosen the locknut
wrench.
G)
NOTE: _________________________
The length of the spring (installed) changes 1.0
mm (0.04 in) per turn of the adjuster .
Measurement length
Standard:
174 mm (6.9 in)
Minimum:
167 mm (6.6 in)
Maximum:
181 mm (7.1 in)
:JW11 J 1---------"0
I.
.-
~I
Locknut:
3-46
IINSP
ADJ
IR I
L...:.....:.=:;....;::;..-J_ _ _.....
*****************************************
Adjustment steps:
Damping
Adjust the damping with the damping adjuster
CD
Hard
Adjuster
position
S.T.D.
4
Soft
Loading condition
Spring length
Damping
adjuster
Solo rider
181 -174 mm
(7.13-6.85 in)
1-3
174-167 mm
(6.85-6.57 in)
3-5
181-174 mm
(7.13-6.85 in)
1-3
0-40kPa
174-167 mm
4. (0-0.4 kg / cm 2,
(6.85-6.57 in)
0-5.7 psi)
3-5
Air pressure
o kPa
1.
2.
3.
(0 kg / cm2,
o psi)
o kPa
(0 kg / cm2,
o psi)
o kPa 2
(0 kg / cm ,
o psi)
With
passenger
With
accessories and
equpment
With accessories,
equipment
and passenger
0
0
0
3-47
TIRE INSPECTION
INSP
ADJ
YB2A3014
TIRE INSPECTION
1. Measure:
-Tire pressure
Out of specification ~ Adjust.
A WARNING
-Tire inflation pressure should be checked
and adjusted when the temperature of the
tire equals the ambient air temperature. Tire
inflation pressure must be adjusted according to total weight of cargo, rider, passenger,
and
accessories
(fairing,
saddlebags, etc. if approved for this model),
and vehicle speed.
- Proper loading of your motorcycle is important for the handling, braking, and other
performance and safety characteristics of
your motorcycle. Do not carry loosely
packed items that can shift. Securely pack
your heaviest items close to the center of
the motorcycle, and distribute the weight
evenly from side to side. Properly adjust the
suspension for your load, and check the
condition and pressure of your tires. NEVER
OVERLOAD YOUR MOTORCYCLE. Make
sure the total weight of the cargo, rider,
passenger, and accessories (fairing, saddlebags, etc. if approved for this model) does
not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could cause tire damage, an accident,
or even injury.
Basic weight:
With oil and full fuel
tank
Maximum load*
Front
Rear
150 kPa
125 kPa
(1.25 kg/cm2, (1.5 kg/cm2,
21 psi)
18 psi)
175 kPa
150 kPa
(1.5 kg/cm 2, (1.75 kg/cm 2,
25 psi)
21 psi)
150 kPa
175 kPa
High speed riding (1.5 kg/cm 2, (1 .75 kg/cm 2,
25 psi)
21 psi)
*Load is the total weight of cargo, rider, passenger,
and accessories.
3-48
TIRE INSPECTION
INSP
ADJ
2. Inspect:
-Tire surfaces
Wear / Damage ~ Replace.
>
CD
Tread depth
~ Side wall
@ Wear indicator
A WARNING
-It is dangerous to ride with a wornout tire.
When a tire tread begins to show lines.
replace the tire immediately.
- Patching a punctured tube is not recommended. If it is absolutely necessary to do
so. use great care and replace the tube as
soon as possible with a good quality
replacement.
- Do not attempt to use tubeless tires on a
wheel designed for tube type tires only. Tire
failure and personal injury may result from
sudden deflation.
Tube type wheel ---> Tube type tire only
Tubeless type wheel--->Tube type or tubeless tire
- Be sure to install the correct tube when using tube type tires.
-After extensive tests. the tires mentioned
below have been approved by Yamaha motor Co . Ltd. for this model. No guarantee
for handling characteristics can be given if
tire combinations other than what is approved are used on this motorcycle. The
front and rear tires should be of the same
manufacture and design.
3-49
IANOSJP I~ I
I
-----------------------------------------------------~.
WHEEL INSPECTION
Front:
Manufacture
Size
Type
BRIDGESTONE
2.7S-21-4PR
TW27
YOKOHAMA
2.7S-21-4PR
E704
Manufacture
Size
Type
BRIDGESTONE
120/80-18 62P
TW30
YOKOHAMA
120/80-18 62P
E704
Rear:
NOTE: _____________________
CD:
:" :".
A, WARNING
-After mounting a tire, ride conservatively
to allow proper tire to rim seating. Failure
to do so may cause an accident resulting
in motorcycle damage and possible operator injury.
-After a tire repair or replacement, be sure
to torque tighten the valve stem locknut
to specification.
CD
341 -009
Y B2A3016
WHEEL INSPECTION
1. Inspect:
-Wheels
Damage/Bends---+ Replace.
A, WARNING
Never attempt even small repairs to the
wheel.
3-50
1 1..0 I
~g~
. ~ .
YB2A3017
Nipple:
2 Nm (0.2 mokg, 1.4 ftolb)
YB3A30 1S
A WARNING
Damaged cable sheath may cause corrosion
and interfere with the cable movement. An
unsafe condition may result so replace such
cable as soon as possible.
1. Inspect:
- Cable sheath
Damage ...... Replace.
2. Check:
- Cable operation
Unsmooth operation ...... Lubricate.
Recommended lubricant:
Yamaha Chain and Cable Lube
or SAE 10W30 motor oil
NOTE: _________________________
Hold cable end high and apply several drops of
lubricant to cable.
3-51
I~gj I ~
. ~ .
YB3A30 19
YB3A5000
SIDESTAND LUBRICATION
Lubricate the sidestand at pivoting points.
Recommended lubricant:
Yamaha Chain and Cable Lube
or SAE 10W30 motor oil
YB2A2005
CD
3-52
Grease nipple
BATTERY INSPECTION
ELECTRICAL
BATTERY INSPECTION
NOTE: _________________________
Since the MF battery is of a sealed-type construction, it is impossible to measure the specific gravity of the electrolyte in order to check the state
of charge in the battery. Therefore, to check the
state of charge in the battery, voltage must be
measured at the battery terminals.
3-53
BATTERY INSPECTION
A WARNING
367-009
1. Remove :
-Side COV9r
(right)
Refer to the "SEAT, FUEL TANK AND
COVER" section .
CD
2. Disconnect:
- Battery leads
~;;III,IIII; !
________
CD
3. Remove:
- Battery
3-54
BATTERY INSPECTION
INSP
ADJ
4. Check:
- Battery condition
Volt meter
*****************************************
Battery condition checking steps:
Connect a digital volt meter to the battery terminals.
13.0
"'"
~
"0
12.5
>
.::;
12.0
'0
i::.
11.5
"c.
0
5
6.5
10
NOTE:
The state of a discharged MF battery can be
checked by measuring open circuit voltage (the
voltage measured with the positive terminals being disconnected).
Hours
Charging time
This varies depending on the temperature. the state of
charge in battery plates and the electrolyte level.
"
~
13
Ambi en!
~'"
12
>
.::;
20C (68FI
"0
'0
c.
Charging time
12.8V or more
No charging is
necessary.
temp erature
~
Open-circuit voltage
10
*****************************************
100
75
50
30 25 20
(%)
-If it is impossible to set the standard charging current, this type of battery charger cannot charge the MF battery.
-When charging the battery, be sure to remove it from the machine. (If charging has
to be done with the battery mounted on the
machine for some reason, be sure to disconnect the wire at the negative terminaL)
-Never remove the sealing plug from the MF
battery.
3-55
BATTERY INSPECTION
Charging
:>
18
~ 17
en
!! 16
"0
> 15
'B 14
Ambient temperature
20 C (68 F)
.~ 13
...........
i:.
~ 12
11
10
10
20
30
40
50
60 Tim. (Minute.
INSP
ADJ
3-56
BATTERY INSPECTION
INSP
ADJ
Charger
AMP meter
NOTE: __________________
Voltage should be measured 30 minutes
after the machine is stopped.
NOTE : __________________
NO
YES
If current does
not exceed standard charging
current after 5
minutes, replace
the battery.
Measure the battery open-circuit voltage after having left the battery
unused for more than 30 minutes.
12.SVor more-Charging is complete.
12.7V or less - Recharging is required.
Under 12.0V-Replace the battery.
3-57
INSP
ADJ
BATTERY INSPECTION
Charging method using a constant-voltage type charger
NOTE: _ _ _ _ _ _ _ _ _ __
YES
~--------I
NOTE: _ _ _ _ _ _ _ __
Set the charging
(maximuml.
NO
~--------~
time at 20 hours
Charger
AMP meter
Volt meter
3-58
IANOSJP I~ I
I
-----------------------------------------------------FUSE INSPECTION
~-
6. Inspect:
- Battery terminal
Dirty terminal--+Clean with wire brush.
Poor connection --+ Correct.
NOTE: _________________________
After cleaning the terminals, apply grease lightly
to the terminals.
7. Install:
-Battery
8. Connect:
- Battery leads
1IIIjlli ________
Connect the positive lead first and then connect the negative lead.
9. Install:
-Side cover (right)
Bolt (side cover):
7 Nm (0.7 m.kg, 5.1 ftlb)
YB30200 1
FUSE INSPECTION
1. Remove :
-Side cover
(right)
Refer to the "SEAT, FUEL TANK AND
COVER" section.
CD
3-59
FUSE INSPECTION
INSP
ADJ
2. Remove:
-Fuse
CD
3. Inspect:
-Fuse
*****************************************
Inspection steps:
Connect the Pocket Tester to the fuse and
check it for continuity.
NOTE: __________________________
Set the tester selector to " Q x 1" position.
Pocket tester:
PIN. YU-03112
PIN. 90890-03112
.If the tester is indicated at 00 . The fuse is blown,
replace it.
*****************************************
4. Replace:
-Blown fuse
*****************************************
IK]I
~:
Fuse:
15 amp" x l pc.
A WARNING
Never use a fuse with a rating other then
specified, or other, material in place of a
fuse. An improper fuse may cause damage
to the electrical system and possible cause
a fire, or the lighting andlor ignition may
cease to function.
3-60-----------------------------
CD
To raise the
beam
To lower the
beam
CD
2. Adjust:
- Headlight beam (horizontal)
CD
To right the
beam
To left the
beam
CD
2. Remove:
- Headlight lens unit
3-61
G)
IANOSJP I~ I
I
-----------------------------------------------------HEADLIGHT BULB REPLACEMENT
3. Disconnect:
- Headlight leads
- Bulb cover ~
~.
CD
4. Remove:
- Bulb holder
-Bulb
Unhook the bulb.
CD
A WARNING
Keep flammable products and your hands
away from the bulb while it is on, it will be
hot. Do not touch the bulb until it cools
down.
IAJ
Turn
5. Install:
- Bulb (new)
Secure the new bulb with the bulb holder.
CD
6. Install:
- Bulb cover
- Headlight leads
7. Install:
- Headlight lens unit
-Cowling (headlight)
Bolt (headlight-upper):
15 Nm (1.5 m.kg, 12 ftlb)
Bolt (headlight-lower):
7 Nm (0.7 m.kg, 5.1 ftlb)
Bolt (cowling):
7 Nm (0.7 m.kg, 5.1 ftlb)
3-62
ENGINE REMOVAL
YB241000
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE: __________________________
It is not necessary to remove the engine in order
to remove the following components:
- Cylinder head
-Cylinder
-Piston
-Clutch
-Oil pump
-C.D.I. magneto
YB241001
ENGINE GUARD
1. Remove:
- Engine guard
CD
YB241002
ENGINE OIL
1. Drain:
- Oil filler cap CD
- Drain plug (g)
Refer to the "ENGINE OIL REPLACEMENT"
section in the CHAPTER 3.
4-1
ENGINE REMOVAL
I I\.1
ENG
YB241003
BATTERY LEADS
1. Disconnect:
- Battery negative lead CD
Refer to the "BATTERY INSPECTION" section in the CHAPTER 3 .
A WARNING
Gasoline is highly flammable. Avoid spilling
fuel on the hot engine.
2. Remove:
- Canister
Q)
YB241005
2. Remove:
CD
- Protector
-Muffler ~
3. Disconnect:
- Rear brake switch rod
4. Remove:
- Exhaust pipe ~
4-2
CD
ENGINE REMOVAL
1 1'.1
ENG
YB241007
2. Drain:
- Fuel (float chamber)
NOTE: _________________________
Place a rag under the over flow hose to absorb
a spilt fuel.
A WARNING
Gasoline is highly flammable. Avoid spilling
fuel on the hot engine.
3. Loosen:
-Screw CD (carburetor joint)
NOTE: _________________________
Move carburetor joint clamp ~ to the rear.
4. Loosen:
-Screw
@ (intake manifold)
5. Disconnect:
ENGINE REMOVAL
4. Disconnect:
-Spark plug cap
(from spark plug)
CD
5. Remove:
-Horn
CD
6. Disconnect:
-Band
- Neutral switch lead (2)
- Stator coil lead
- Neutral switch lead
- Charge coil lead @
- Pulser coil lead @
CD
7. Disconnect:
- Starter motor lead
(from starter motor and clamps)
CD
8. Remove:
- Starter motor
(2)
9. Disconnect:
-Wire earth lead
- Starter motor lead (2)
(from the crankcase)
CD
4-4
1 ENG I
ENGINE REMOVAL
\,.1
Y B241010
DRIVE CHAIN
1. Remove:
-Cotter pin
2. Loosen:
- Axle nut
CD
C2)
3. Remove:
-Shift arm
Footrest C2) (left)
Crankcase cover 2
CD
4. Remove:
-Bolts
Sprocket holder C2)
Drive chain (with drive sprocket)
CD
NOTE: _________________________
Loosen the bolt while applying the rear brake.
5. Remove:
CD
Adjuster
Pin C2)
Compression spring
6. Remove:
-Circlip @
-Washer
Brake pedal shaft
Rear brake pedal (j)
7. Disconnect:
Spring @
NOTE: _________________________
When removing the brake pedal, pass the pedal
boss over the relay arm shaft cover and
remove backward.
4-5
ENGINE REMOVAL
1 ENG
1,..1
YB241011
ENGINE REMOVAL
1. Place suitable stand under the frame and
engine.
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
2. Remove:
-Mounting bolts
3. Remove:
-Mounting bolt
CD
CD (rear-lower)
4. Remove:
-Mounting bolts
5. Remove:
- Pivot shaft
(front-lower)
CD
(front-upper)
CD
NOTE: __________________________
The engine and swingarm are installed using the
same pivot shaft. Therefore, take care so that the
pivot shaft is p~!led, not entirely out, but for
enough to set the engine free.
4-6
ENGINE REMOVAL
6. Remove:
Engine assembly
(from right side of motorcycle)
NOTE: __________________________
After removing the engine, hold the other side
of the swingarm using an appropriate shaft.
4-7
ENGINE DISASSEMBLY
ENG
Y B342002
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER AND PISTON
NOTE: _________________________
With the engine mounted, the cylinder head,
camshaft and cylinder can be maintained by
removing the following parts.
-Side covers
-Seat
-Air scoops
-Fuel tank
- Exhaust pipe
- Carburetor
- Clutch cable
-Spark plug lead
-Horn
- Engine mount stay (from upper)
1. Remove:
- Spark plug
CD
2. Remove:
-Intake manifold
3. Remove :
-Timing plug
-Plug (center)
4-8
CD
CD
(2)
ENGINE DISASSEMBLY
ENG
1,.1
4. Remove:
-Tappet cover (intake) CD
-Tappet cover (exhaust) <Z>
5. Remove:
- Cylinder head side cover
-O-ring <Z>
CD
6. Align:
- "Tn mark on the rotor
With the stationary pointer on the crankcase
cover.
*****************************************
Toe
alignment steps:
Turn the crankshaft counterclockwise with
wrench .
Align the "Tn mark CD on the rotor with the
stationary pointer <Z> on the crankcase cover.
When the "Tn mark is aligned with the stationary pointer, the piston is at Top Dead Center
(TOC).
NOTE: __________________________
TOC on compression stroke check:
- Both rocker arms must have a valve clearance
when the cam sprocket match mark @ is
aligned with the cylinder head match mark @.
-If not, give the crankshaft one counterclockwise
turn too meet above condition.
4-9 *****************************************
ENGINE DISASSEMBLY
7. Loosen:
-Cap bolt
CD
I ENG
1,\.1
(chain tensioner)
8. Remove:
- Chain tensioner ~
9. Remove:
-Solt CD
-Cam sprocket ~
NOTE: __________________________
- Fasten a safety wire @ to the timing chain to
prevent if from falling into the crankcase.
10. Remove:
-Solts
NOTE: _________________________
11. Remove:
\.
- Cylinder head
4-10
CD
ENGINE DISASSEMBLY
12. Remove:
-Timing chain guide
CD (exhaust)
- Dowel pins ~
-Grommet
-Gasket @ (cylinder head)
13. Remove:
-Bolts
- Clutch cable holder ~
CD
14. Remove:
-Cylinder
CD
15. Remove:
-O-ring
- Dowel pins ~
-Gasket
(cylinder)
CD
4-11
ENGINE DISASSEMBLY
16. Remove:
- Piston pin circlip
- Piston pin (2)
-Piston
ENG
1"
..I
CD
NOTE: _________________________
- Before removing the piston pin circlip, cover the
crankcase with a clean rag to prevent the circlip from falling into the crankcase cavity.
- Before removing the piston pin, deburr the clip
grooved and pin hole area. If the piston pin
groove is deburred and piston pin is still difficult
to remove, use the piston pin puller.
YB342003
CD
2. Remove:
-Crankcase cover (2) (left)
NOTE: _________________________
Working in a crisscross pattern, loosen the bolts
1/ 4 turn each. Remove them after all are
loosened.
4-12
ENGINE DISASSEMBLY
I 1,..1
ENG
3. Remove:
- Dowel pins CD
-Gasket (2) (crankcase cover)
-Coller
-Shaft @
- Starter idle gear 1 @
4. Remove:
-Bolt CD (rotor)
NOTE: __________________________
Loosen the bolt (rotor) while holding the rotor
with the rotor holder (2).
~ Rotor holder:
,j"PIN. YS-01880, 90890-01701
on the rotor.
5. Remove:
-Rotor CD
-Woodruff key (2)
Use the rotor holder
Rotor puller:
IIIIIIII~!;
________
4-13
ENGINE DISASSEMBLY
6. Remove:
-Wheel gear
-Washer ~
ENG [ , . [
CD
7. Remove:
-Chain guide
(intake)
-Timing chain ~
CD
YB342004
OIL FILTER
1. Remove:
- Oil filter cover
2. Remove:
- Oil filter
-O-rings ~
CD
4-14
CD
ENGINE DISASSEMBLY
ENG
I~.I
1. Remove:
- Crankcase cover
CD
(right)
NOTE: _________________________
Working in a crisscross pattern, loosen the bolts
1/4 turn each. Remove them after all are
loosened.
2. Remove:
CD
- Dowel pins
-Gasket ~ (crankcase cover)
3. Remove:
-Bolts
-Clutch springs ~
-Pressure plate @
- Friction plate @ (type A)
-Cushion spring
-Clutch plate
- Friction plate (j) (type B)
-Ball
-Push rod 2
CD
NOTE: _________________________
Working in a crisscross pattern, loosen the bolts
1/4 turn each. Remove them after all are
loosened.
4-15
ENGINE DISASSEMBLY
I 1'.1
4. Remove:
- Push lever assembly
ENG
CD
5. Straighten:
-Lock washer tab
CD
6. Loosen:
- Nut ~ (clutch boss)
NOTE: __________________________
Loosen the nut (clutch boss) while holding the
clutch boss with universal clutch holder @.
7. Remove:
- Nut
(clutch boss)
- Lock washer ~
-Clutch boss @
- Thrust plate @
- Primary driven gear
CD
8. Remove:
-Oil pump gear cover
CD
NOTE: _________________________
Remove the cover by lifting upward as shown .
4-16
ENGINE DISASSEMBLY
9. Remove:
-Oil pump assembly
I ENG I\.1
G)
10. Remove:
-Gasket G) (oil pump)
11. Straighten:
- Lock washer tabs G)
12. Loosen:
- Nut ~ (crankshaft)
- Nut
(balancer shaft)
NOTE: __________________________
4-17
ENG
ENGINE DISASSEMBLY
1\,.1
13. Remove:
- Primary drive gear
- Claw washer ~
- Balancer drive gear and buffer boss
-Key @
- Plate washer
-Plate
- Balancer gear (j)
-Key @
CD
SHIFT SHAFT
NOTE: _________________________
1. Remove:
- Shift shaft
-Washer ~
- Return spring @
- Stopper lever @
-Washer
-Circlip
-Torsion spring (j)
-Collar @
CD
NOTE: __________________________
Push the shift shaft arm and the stopper lever to
the arrow direction and remove them from the
segment.
4-18
ENGINE DISASSEMBLY
I I~_I
ENG
2. Remove:
-Segment
Use the torx wrench to remove.
CD
NOTE: __________________________
When removing the segment, the dowel pin will
fall off. Take care not to lose the pin.
3. Remove:
-Circlip
-Collar ~ (drive axle)
-Circlip
CD
YB242009
CRANKCASE
1. Remove:
-Solts (crankcase)
NOTE: _________________________
- Loosen the bolts 1/4 turn each and remove them
after all are loosened.
- Loosen the bolts starting with the highest numbered one.
-The embossed numbers in the crankcase designate the tightening sequence .
4-19
ENGINE DISASSEMBLY
I 1,\..
ENG
2. Remove:
- Crankcase:
The slot
for separating the crankcase is
provided. Using the screwdriver ~ ,
separate the case with even force applied to
both sides .
CD
CD
3. Remove:
- Dowel pins
CD
4:~)
:;;
YB242010
CD
2. Remove:
- Main axle assembly
4-20
CD
ENG
ENGINE DISASSEMBLY
3. Remove:
Drive axle assembly
Washer ~
1,.1
CD
4. Remove:
Balancer shaft
CD
5. Remove:
Neutral switch
CD
YB242011
CRANKSHAFT
1. Remove:
Crankshaft assembly
Use the crankcase separating tool ~ and
adapter @.
CD
NOTE: _________________________
Tighten the tool holding bolts, but make sure that
the tool body is vertical with the crankshaft. If
necessary, one screw may be backed out slightly to level tool body.
4-21
ENGINE DISASSEMBLY
2. Remove:
-Dowel pin G)
- Pin with hole ~
- Compression spring
1. Straighten:
-Lock washer tab
G)
2. Remove:
- Lock washer ~
-Plate @
3. Remove:
-Camshaft G)
-Collar ~
NOTE: _________________________
Remove the camshaft and collar by using 10 mm
(0.4 in) bolt @.
4-22
ENGINE DISASSEMBLY
ENG
4. Remove:
- Rocker arm shaft
-Rocker arm
NOTE: _________________________
Remove the rocker arm shaft by the slide hamand weight ~.
mer bolt
CD
Y8342012
VALVES
NOTE: __________________________
Before removing the internal parts (valve, valve
spring, valve seat etc.) of the cylinder head.
The valve sealing should be checked.
1. Check:
-Valve sealing
Leakage at valve seat-+ Inspect the valve
face, valve seat and valve seat width.
Refer to the "INSPECTION AND REPAIRVALVE SEAT".
*****************************************
Checking steps:
Pour a clean solvent
into the intake and exhaust ports .
Check the valve sealing.
There should be no leakage at the valve seat
CD
~.
*****************************************
4-23
ENGINE DISASSEMBLY
2. Remove:
-Valve cotters
ENG
I~.I
CD
NOTE: _________________________
Remove the valve cotters while compressing the
valve spring with the valve spring compressor
~.
3. Remove:
-Valve retainer
-Valve spring ~ (outer)
-Valve spring
(inner)
-Valve @
-Oil seal @
CD
- Spring seat
NOTE: _________________________
Identify each part position very carefully so that
it can be reinstalled in its original place.
4-24
ENG
I~.I
Y B243001
CD.
NOTE: _________________________
Do not use a sharp instrument and avoid damaging or scratching:
-Spark plug thread
-Valve seat
2. Inspect:
-Cylinder head
Scratches/ Damage~ Replace.
3. Measure:
-Warpage
Out of specification ~ Resurface.
Cylinder head warpage :
Less than 0.03 mm (0.0012 in)
4. Resurface:
-Cylinder head
********* * ********************* * *********
.....\........-. .: ....
"
::'.:
. .".
..-:".":".:.. :":":"::".
"
Resurfacement steps:
Place a 400-600 grit wet sandpaper on the surface plate, and resurface the head using a
figure-eight sanding pattern .
\~ ~ ~:.: ;~
.......:...
..... .... ..
:.
: .... :. :.:::: .. ::
.,
....:":.....:.:.:)~
4-25
ENG
1'.1
NOTE: __________________________
Rotate the head several times to avoid removing
too much material from one side .
********** ** ********************** * ***** *
YB243002
VALVE SEAT
1. Eliminate:
- Carbon deposit
(from valve face and valve seat)
2. Inspect:
-Valve seat
Pitting/Wear--> Refase the valve seat.
3. Measure:
-Valve seat width
Out of specification --> Reface the valve seat.
Measurement steps:
Apply the Mechanic's bluing dye (Dykem)
to the valve face.
Install the valve into the cylinder head.
Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
Measure the valve seat width. Wherever the
valve seat and valve face made contact, bluding will have been removed.
If the valve seat width is too wide, too narrow,
or seat has not centered, the valve seat must
be refaced.
*********** ******************************
CD
4-26
1 I,.1
ENG
4. Reface:
-Valve seat
Use a 30, 45 and 60 valve seat cutter
CD.
PIN. YM-91043
When twisting cutter, keep an even downward pressure (4 - 5 kg) to prevent chatter
marks.
Cutter
30
45
60
*****************************************
Refacing steps:
~ Valve seat is centered on valve face but
it is too wide.
Valve seat cutter set
Use
lightly
30 cutter
60 0 cutter
Desire result
To reduce valve seat
width to 1.0 mm
(0.039 in).
lID Valve
4-27
45 0 cutter
Desired result
To achieve a uniform
valve seat width of
1.0 mm (0.039 in).
[9
......... ...
[QJ
Qj
I
I
I
Desired result
To center the seat
and to achieve its
width of 1.0 mm
(0.039 in).
I
I
1,.1
~~
ENG
......................................
*****************************************
5. Lap :
-Valve face
-Valve seat
NOTE: _________________________
After refacing the valve seat or replacing the valve
and valve guide, the valve seat and valve face
should be lapped.
************ * ****************************
Lapping steps:
e Apply a coarse lapping compound to the valve
face.
Be sure no compound enters the gap between the valve stem and guide.
302 -024
4-28
ENG
1'.1
NOTE: _________________________
YB24:JOO:J
302-029
4-29
ENG
1'.1
2. Replace:
-Valve guide
********** * ************ ******************
Replacement steps:
NOTE: __________________________
CD .
CD .
NOTE: _________________________
Reface the valve seat after replacing the valve
guide.
3. Eliminate:
- Carbon deposit
(from valve face)
4. Inspect:
-Valve face
Pitting/Wear~Grind the face.
-Valve stem end
Mushroom shap or diameter larger than rest
of stem~Replace.
4-30
1 1,..1
ENG
5. Measure:
- Margin thickness
Out of specification --> Replace.
@--H-
Margin thickness:
0.8-1.2 mm (0.03-0.05 in)
~45
"-I..
302 -000
6. Measure:
-Runout (valve stem)
Out of specification--> Replace.
Runout:
Less than 0.010 mm (0.0004 in)
/
302-004
NOTE: _________________________
-Always replace the guide if the valve is replaced.
- Always replace the oil seal if the valve is
removed.
Y 8243004
VALVE SPRING
1. Measure:
- Free length
(valve spring)
Out of specification --> Replace.
302-005
I~
4-31
Outer spring
Intake
36.17 mm
(1.424 in)
36.63 mm
(1.442 in)
Exhaust
36.17 mm
(1.424 in)
36.63 mm
(1.442 in)
1 I\.,1
ENG
2. Measure:
-Compressed force (valve spring)
Out of specification ~ Replace.
Installed
G)
length
302-006
I~
Compressed force:
Outer spring at
Inner spring at
30.5 mm (1.20 in) 36.6 mm (1.44 in)
Intake
7.7-9.4 kg
(16.98 - 20.72 Ib)
13.1 -16.1 kg
(28.88 - 35.49 Ib)
Exhaust
7.7-9.4 kg
(16.98-20.72 Ib)
13.1 -16.1 kg
(28.88 - 35.49 Ib)
3. Measure:
_4-i-oI-@
- Spring tilt
Out of specification~ Replace.
Spring tilt:
Intake:
Less than 1.6 mm (0.063 in)
Exhaust:
Less than 1.6 mm (0.063 in)
302 -028
YB243005
CAMSHAFT
1. Inspect:
-Cam lobs
Pitting / Scratches / Blue
Replace .
discoloration ~
2. Measure:
- Cam lobes length and @
Out of specification ~ Replace.
Cam lobes length:
Intake:
30.10-30.20 mm
(1.185-1.189 in)
@ 36.51 - 36.61 mm
(1.437 -1.441 in)
4-32
IENG 1,.1
3. Measure:
Runout (camshaft)
Out of specification-> Replace.
Runout (camshaft):
Less than 0.03 mm (0.0012 in)
4. Measure:
.Camshaft-to-cap clearance
Out of specification->Measure bearing diameter (camshaft).
Camshaft-to-cap clearance:
0.020-0.061 mm
(0.0008 - 0.0024 in)
5. Measure:
Bearing diameter
(camshaft)
Out of specification->Replace camshaft.
Within specification-> Replace cap (coller).
4-33
ENG
1,.1
2. Inspect:
- Rocker arm shaft hole
- Cam lobe contact surface
-Adjuster surface
Wear / Pitting/ Scratches/ Blue discoloration
-+ Replace, then inspect lubrication system.
CD
3. Measure:
- Arm-to-shaft clearance.
Arm-to-shaft clearance =
Rocker arm inside diameter @Rocker arm shaft outside diameter
Arm-to-shaft clearance:
0.009-0.037 mm
(0.0004 - 0.0015 in)
YB243007
343-007
2. Inspect:
Cam sprocket
Wear / Damage-+ Replace cam sprocket and
timing chain as a set.
CD
1/4 tooth
Roller
~ Correct
@ Sprocket
343-014
4-34
ENG
1,.1
3. Inspect:
-Chain guide G) (exhaust side)
-Chain guide ~ (intake side)
Wear / Damage--. Replace .
4. Check:
-Timing chain tensioner play
*****************************************
Checking steps:
While pressing the tensioner rod lightly with
fingers, use a thin screwdriver G) and wind the
tensioner rod up fully clockwise.
When releasing the screwdriver by pressing
lightly with fingers, make sure that the tensioner
rod will come out smoothly.
If not, replace the tensioner assembly.
*****************************************
YB243008
307-002
4-35
ENG
1'\.1
4. Inspect:
Cylinder wall
Wear / Scratches~Rebore
or replace.
5. Measure:
Piston-to-cylinder clearance
*****************************************
Measurement steps:
First steps
Measure the cylinder bore "C" with a cylinder
bore gauge.
304 -011
NOTE: __________________________
Measure the cylinder bore "C" in parallel to and
at right angles to the crankshaft.
Then, find the average of the measurements.
C=(X+Y)/2
If out of the specification, rebore or replace the
cylinder, and the piston and piston rings as a
set.
2nd steps
Measure the piston skirt diameter "P" with a
micrometer.
304-011
4-36
ENG [ , . [
3rd steps
Find the piston-to-cylinder clearance with following formula.
Piston-to-cylinder clearance =
Cylinder bore "C"Piston skirt diameter "P"
Piston-to-cylinder clearance:
0.035-0.055 mm
(0.0014- 0.0022 in)
< Limit: 0.10 mm (0.004 in) >
PISTON RING
1. Measure:
Side clearance
Out of specification-->Replace piston and
piston ring as a set.
NOTE: __________________________
Clean carbon from piston ring grooves and rings
before measuring side clearance.
Side clearance:
Top ring:
0.03 - 0.07 mm
(0.001-0.003 in)
2nd ring:
(0.02-0.06 mm)
(0.001 - 0.002 in)
2. Position:
Piston ring
(into the cylinder)
NOTE: __________________________
Push the ring with the piston crown so that the
ring will be at a right angle to cylinder bore.
4-37
ENG
3. Measure:
-End gap
Out of specification~ Replace.
NOTE: __________________________
You cannot measure end gap on expander spacer
of oil control ring. If oil control ring rails show excessive gap, replace all three rings.
End gap:
Top ring:
0.15 - 0.30 mm
(0.006 - 0.012 in)
2nd ring:
0.15-0.30 mm
(0.006 - 0.012 in)
Oil ring:
YB243010
PISTON PIN
1. Inspect:
- Piston pin
Blue discoloration / groove~ Replace, then
inspect lubrication system.
CD
2. Measure:
- Piston-pin outside diameter
Out of specification ~ Replace.
CD
307018
Micrometers
3. Measure:
- Piston-pin bore inside diameter
Out of specification ~ Replace.
4-38
ENG
I'~I
CRANKSHAFT
1. Measure:
- Crank width
Out of specification ~ Replace crankshaft.
-4-------~
Crank width:
55.95-56.00 mm
(2.203 - 2.205 in)
-Runout
Out of specification -> Replace crankshaft
and / or bearing.
I~
Runout limit:
0.03 mm 10.001 in)
2. Inspect
- Crankshaft sprocket CD
Wear / Oamage->Replace crankshaft.
- Crank bearing (2)
Abnormal noise / Turn roughly / Free play->
Replace crankshaft.
3. Inspect:
-Crank bearing CD
Abnormal noise / Turn roughly / Free play--+
Replace crankshaft.
w:=~~1l'J
!AI
4-39
Free play
ENG
1 '
.. I
*****************************************
CD
*****************************************
CD
2. Inspect:
CD
Buffer boss
Compression spring ~
Oowel pin
Wear / Cracks/ Oamage-> Replace.
3. Inspect:
CD
Match marks
If they are not aligned->Align match marks
as showl.
YB243013
PRIMARY DRIVE
1. Inspect:
Primary drive gear teeth
Primary driven gear teeth ~
Wear / Oamage-> Replace both gears.
Excessive noises during operation -> Replace
both gears.
CD
4-40
I I~.I
ENG
YB243014
CLUTCH
1. Inspect:
Friction plate
Damage / Wear-+ Replace friction plate as a
set.
2. Measure:
Friction plate thickness
Out of specification -+ Replace friction plate
as a set.
Measure at all four points.
311000
Thickness
Wear
limit
Type "A"
(1 pes.)
2.90 - 3.10 mm
(0.114-0.122 in)
2.8 mm
(0.110 in)
Type "8"
(5 pes.)
2.90 - 3.10 mm
(0.114 - 0.122 in)
2.8 mm
(0.110 in)
3. Inspect:
Clutch plate
Damage-+Replace clutch plate as a set.
4. Measure:
Clutch plate warpage
Out of specification -+ Replace clutch plate
as a set.
Use a surface plate and feeler gauge
CD.
Warp limit:
Less than 0.2 mm (0.008 in)
31HlO2
4-41
ENG
I~.I
5. Inspect:
-Clutch spring
Damage-+Replace as a set.
6. Measure:
- Clutch spring free length
Out of specification -+ Replace spring as a
set.
7. Inspect:
- Dogs on the primary driven gear
Scoring/Wear / Damage-+ Deburr or replace.
- Clutch boss splines ~
Scoring/Wear / Damage -+ Replace clutch
boss.
NOTE: _________________________
CD
8. Check:
-Circumferential play
Free play exists-+Replace.
4-42
IENG 1'.1
9. Inspect:
- Pressure plate
- Push plate
-O-ring @
-Push rod 1
-Ball
Wear / Damage--> Replace.
-Push rod 2
- Push lever (j)
Wear / Bend / Damage --> Replace.
CV
CD
YB24301S
CD
CV
2. Inspect:
-Shift cam groove
- Dowel pin
-Shift cam segment @
Wear / Damage--> Replace.
CV
CD
3. Check:
- Shift fork movement
Unsmooth operation --> Replace shift fork
and/or guide bar.
4-43
A WARNING
Do not attempt to straighten a bent guide
bar.
5. Measure:
- Runout (drive axle and main axle)
Out of specification~ Replace.
I?JJ
Runout:
Less than 0.08 mm (0.003 in)
A WARNING
Do not attempt to straighten a bent axle.
'--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _3_'9_-00_'...
6. Inspect:
-Gear teeth
Blue discoloration/ Pitting/Wear~ Replace.
-Mated dogs
Rounded edges/Cracks/Missing portions~
Replace.
*****************************************
Reassembling point:
Press the 2nd pinion gear
~ as shown.
G)
*****************************************
4-44
ENG
1\,.1
7. Inspect:
- Shift shaft CD
- Stopper lever
Damage/ Bends/Wear~ Replace.
- Torsion spring
- Return spring @
Cracks/ Damage~ Replace.
YB243016
- Side clearance
(between outer rotor
~~~~~~
Out of
specifications~ Replace
oil pump.
Tip clearance:
0.15 mm (0.006 in)
Side clearance:
0.04-0.09 mm (0.002-0.004 in)
2. Inspect:
-Oil pump dirven gear CD
-Oil pump
Wear / Cracks/ Damage~ Replace.
4-45
I I~.I
ENG
YB243012
CD
2. Inspect:
- Starter wheel gear
(contacting surfaces)
Pitting/Wear / Damage~ Replace.
3. Inspect:
- Starter clutch assembly
-Dowel pin 0
- Compression spring @
-Spring cap
Wear / Damage~ Replace.
CD
4. Check:
- Starter clutch operation
*****************************************
Checking steps:
Install the starter wheel gear to the starter
clutch, and hold the starter clutch.
When turning the starter wheel gear clockwise
IA], the starter clutch and the wheel gear should
be engaged.
If not, the starter clutch is faulty. Replace it.
When turning the starter wheel gear counterclockwise ffi), the starter clutch gear should turn
freely.
If not, the starter clutch is faulty. Replace it.
*****************************************
4-46
ENG
1'\.1
5. Inspect:
CD
- Pulser coil
-Charge/startor coil ~
Damage~ Replace.
Y8243018
CRANKCASE
1. Thoroughly wash the case halves
solvent.
mild
2. Clean all the gasket mating surface and crankcase mating surface thoroughly.
3. Inspect:
-Crankcase
Cracks/ Damage~ Replace.
-Oil delivery passages
Clog~Blow out with compressed air.
YB243019
Do not use compressed air to spin the bearings dry. This causes damage to the
surfaces.
2. Inspect:
-Oil seals
Damage/Wear~ Replace.
4-47
1 ENG
1,..1
YB243020
4-48
ENG
I~.I
CD
Valve
~ Valve
@ Valve
@ Valve
Valve
@ Valve
(J) Valve
@ Valve (exhaust)
cotter
spring retainer
stem seat
spring (inner)
spring (outer)
spring seat
(intake)
QD
@
@
1r-~-3-.5-N-m-(1-.-35-m-.k-g-,-1-0-ft-.-lb--')
@ Circlip
@ Valve guide
@ Camshaft
Locknut
Adjuster
Rocker arm
Rocker arm shaft (intake)
O-ring
Rocker arm shaft (exhaust)
Collar
@) Plate
@ Lock washer
II--- 1
~ Jl~e
s-@
4-49
ENG
I~.I
YB244000
A WARNING
For engine reassembly, replace the following parts with new ones.
-O-ring
-Gasket
-Oil seal
- Copper washer
-Lock washer
-Circlip
YB344002
VALVES
1. Oeburr:
-Valve stem end
Use an oil stone to smooth the stem end .
302-003
2 . Apply:
- Molybdenum disulfide oil
(onto valve stem and oil seal)
3. Install:
-Valve
-Valve
-Valve
-Valve
-Valve
-Valve
4-50
CD
spring seat
stem seal ~
spring (inner)
spring (outer)
retainer
I'-I
4. Install:
-Valve cotters
(f)
fac-
CD
NOTE: _________________________
Install the valve cotters while compressing the
valve spring with the valve spring compressor
NOTE: _________________________
Do not hit so much as to damage the valve.
ROCKER ARM
1. Lubricate:
-Molybdenum disulfide oil
(to the rocker arm, rocker arm shaft and
a-ring)
2. Install:
-a-ring
- Rocker
- Rocker
- Rocker
4-51
- Rocker
CD
arm
arm shaft
arm @
arm shaft
(exhaust l
(intake}
ENG
NOTE: _________________________
3. Lubricate:
-4-stroke engine oil
(to the camshaft, collar and pin)
4. Install:
- Camshaft
-Collar ~
-Pin @
G)
NOTE: _________________________
Align the camshaft pin @ with the match mark
on the cylinder head and install the pin.
5. Install:
-Plate G)
- Lock washer ~
Bolt @ (camshaft):
8 Nm (0.8 m.kg, 5.8 ttlb)
A WARNING
Always use a new lock washer.
ENG
1,.1
CRANKSHAFT
G) Crank pin
~ Crank (left)
Connecting rod
Big end bearing
5 Crankshaft bearing
6 Compression spring
(j) Pin with hole
Dowel pin
CRANK WIDTH:
<55.95-56.00 mm (2.203-;-2.205 in
RUNOUT LIMIT:
<0.03 mm (0.0012 in
~A
~
Ir-"B-630-6-9--C-4-Po"""l
C"
B6305-9-C3PO
m
4
4-53
ENG
1'.1
CRANKSHAFT
1. Attach:
-Crankshaft installing tool
NOTE: __________________________
Hold the connecting rod at top dead center with
one hand while turning the nut of the installing
tool with the other. Operate the installing tool until
the crankshaft bottoms against the bearing.
,;I .l lil,.;i.I
_ _ _ _ _ _ __
3. Install:
- Compression spring
- Pin with hole ~
-Dowel pin
4-54
CD
IENG I"~I
4. Check:
Pin with hole play
After installing, make sure that the pin with
hole operates smoothly in the arrow
direction.
4-55
ENG
1,.1
G)
(2)
@
@
@
(j)
@ Bearing
Drive sprocket
Oil seal
Bearing
2nd wheel gear
Drive axle
5th wheel gear
3rd wheel gear
4th wheel gear
6th wheel gear
1st wheel gear
@
@
@
@
@)
@l
@ Balancer weight
@ Bearing
Oil seal
Bearing
2nd pinion gear
5th pinion gear
3rd pinion gear
4th pinion gear
Main axle
Bearing
Bearing
1862031
86204
19
&~,
~1
1 86304G 1
~~~
\
1 S3-15-2S-3.5-HS
186205SH21
4-57
CD
Shift
~ Shift
Q) Shift
@ Shift
@ Shift
Shift
fork
fork
fork
cam
fork
fork
m
4-58
ENG
I~.I
2. Install:
- Balancer shaft
CD
3. Apply:
-Molybdenum disulfide oil
(onto drive axle, main axle and gears)
4. Install:
- Drive axle assembly
- Main axle assembly ~
CD
CD
-Circlip
Install the chamfered side ~ facing the
gear @ .
A WARNING
Always use a new circlip.
4-59
ell
CAUTI<.lN:
Do not expand the circlip than needed.
5. Install:
-Washer CD
- Drive axle assembly
ell
6. Install:
- Main axle assembly
CD
7. Apply:
-4-stroke engine oil
(onto shift fork guide bars)
8. Install:
-Shift fork
-Shift fork
-Shift fork
-Shift cam
-Shift fork
-Shift fork
CD
ell
3
2
1 Q)
@
guide bar (long)
guide bar (short)
NOTE: __________________________
4-60
----------------------------------
ENG
9. Check:
-Transmission operation
Unsmooth operation ~ Repair.
4-61
1".1
CD
(2)
ENG
1 ,
.. I
Crankcase (right)
Dowel pin
Crankcase ventilation hose
Crankcase (left)
Hose holder
IA I TIGHTENING SEQUENCE:
---~'1111
7 Nm
4-62
IENG I~.I
CRANKCASE (RIGHT)
1. Apply:
-Sealant G)
(onto mating surfaces of both case halves)
Sealant (quick gasket):
PIN. ACC-11001-01
Yamaha Bond No. 1215:
PIN. 90890-85505
NOTE: _________________________
DO NOT ALLOW any sealant to come in contact
with the oil gallery.
2. Install:
- Dowel pins
G) -
NOTE: ________________________
Bolts (crankcase):
7 Nm (0.7 m.kg, 5.1 ftlb)
5. Apply:
-4-stroke engine oil
(to the crank pin, bearing and oil delivery
hole)
6. Check:
-Crankshaft and transmission operation
Unsmooth operation ---> Repair.
4-63
CD
Segment
112 Nm
1
CD
:><,,-,
@wi l
l
@i
4-64
1 1".1
ENG
ENG
1\,.1
SHIFT SHAFT
1. Install:
-Circlip
(to drive axle)
-Collar (2)
-Circlip
CD
2. Install:
-Segment
-Dowel pin
- Dowel pin
CD
(2) (long)
@ (short)
NOTE: __________________________
Install the dowel pin
position .
(2) (long)
3. Install:
-Segment
CD
NOTE: _________________________
Fit the dowel pin (2) (long) on the segment to the
locating hole
and install the segment.
4. Tighten:
-Screw
CD
Screw:
12 Nm (12 m.kg, 8.7 ftlbl
USE LOCTITE@
5. Install:
-Shift shaft
-Collar (2)
-Torsion spring
-Circlip @
-Washer @
CD
- Stopper lever
- Return spring
-Washer
(j)
NOTE: _________________________
Install the torsion spring
4-65 sides of the guide plate
firmly to hold
@.
both
ENG
1'..
6. Install:
CD
Stopper lever
- Return spring ~
-Shift shaft Q)
-Torsion spring @
NOTE: ___________________________
CD
4-66
ENG
BALANCER GEAR
CD
Key
Lock washer
Nut
Plate washer
Balancer drive gear
(j)
(jJ)
@
@
Buffer boss
Claw washer
Key
Primary drive gear
Lock washer
Nut
r--r------,~
IA I USE NEW ONE 1
~~~
I
4-67
ENG
\,.1
CD
Clutch spring
Push rod 1
Push lever
Primary drive gear
@ Oil pump gear cover
@ Oil pump driven gear
@l Oil pump
> Gasket
A)
Clutch plate
Friction plate (type B)
Thrust washer
@ Ball
@ Push rod 2
FRICTION PLATE:
Type
Thickness
Wear Limit
2.90-3.10 mm
(0.114-0.122 in)
2.90-3.10 mm
(0.114-0.122 in)
1 pc.
B
5 pcs.
CLUTCH PLATE
C WARPAGE LIMIT:
0.2 mm (O.OOS in)
11
r--r------;~~~/~
>
"~O) ~ ~11-2
~ f@o
.
~.
~r--------'1
({!Jff!~ " ,.
m "'" \ I
I
J
-N-m-(1-.2-m-.-k-g,-S-.
7-ft-.I-b)""11
SO'4-26-6-HS
~/
r-17-0-N-m-(-7-.0-m-.k-g-,-50-f-t.-Ib-):"'I
/ ' '1!'f1
oo~
4-68
1 1,.1
ENG
NOTE: __________________________
-When installing the drive gear, align the punched
mark @ on the drive gear and the buffer boss
with the punched mark @ on the balancer gear.
- Place a folded rag or aluminum plate between
the teeth of the balancer drive gear and balancer
gear.
-Take care not to damage the gear teeth.
4-69
IENG I ~..I
3. Apply:
-4-stroke engine oil
(to the oil pump inner parts)
4. Install:
- Rotor housing CD
- Outer rotor ~
-Inner rotor @
- Dowel pins
-Oil pump driven gear
-Dowel pin
-Oil pump cover (J)
-Screw
Screw:
7 Nm (0.7 mkg, 5.1 ftlb)
5. Apply:
-4-stroke engine oil
(to the oil passages in the crankcase)
6. Apply:
-4-stroke engine oil
(to the oil passages in the oil pump)
7. Install:
-Gasket CD
-Oil pump assembly ~
-Bolts @
-Oil pump driven gear cover
4-70
ENG [\,.[
8. Apply:
-4-stroke engine oil
(onto journal and gear teeth)
9. Install:
- Primary driven gear G)
-Thrust plate (2)
-Clutch boss assembly
- Lock washer
-Nut @ (clutch boss)
NOTE: __________________________
Fit the tabs of the lock washer to the groove of
the clutch boss.
10. Tighten:
-Nut G) (clutch boss)
NOTE: __________________________
Tighten the nut (clutch boss) while holding the
clutch boss with the universal clutch holder (2).
4-71
IENG 1'.1
CD
14. Install:
- Push rod 2 CD
-Sail (2)
-Friction plate @ (type S)
- Clutch plates @
- Cushion spring @
- Friction plate (type A)
- Pressu re plate (j)
- Clutch spring
-Solts
NOTE: _________________________
- Apply 4-stroke engine oil to the plates and install
-Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate.
3 11 -001
4-72
Friction Plate
Type "A"
Type "8"
Quantity
1 pes.
5 pes.
Inside
Diameter "0"
107 mm
(4.21 in)
99 mm
(3.90 in)
1 I\,.1
ENG
NOTE: __________________________
Tighten the bolts in a crisscross pattern.
15. Check:
- Push lever position
- Push the push lever ass'y to the arrow direction and make sure that match marks should
be aligned.
Not aligned~Adjust.
CD
CZ)
16. Adjust:
- Push lever position
*****************************************
Adjustment steps:
CD.
1 1;;;; _ _ _ _ _ _ __
Do not overtighten the adjuster ~ and remove the free play between push rods.
'v
~~
*****************************************
17. Install:
- Dowel pins
-Gasket ~ (crankcase cover)
CD
4-73
CD
ENG
[\,~[
(right)
2. Install:
-Oil filter
-O-rings (2)
CD
3. Install:
-Oil filter cover
CD
Bolt
(oil filter coverboth side):
7 Nm (0.7 m.kg, 5.1 ftlb)
Bolt @ (oil filter cover-lower):
10 Nm (1.0 m.kg, 7.2 ftlb)
4-74
CD Timing chain
(2) Timing cha in guide (intake)
Woodruff key
@ Washer
@ Starter wheel gear
@
@
@ Starter clutch
Compression spring
Rotor
Starter idle gear 1
Shaft
Collar
Charge coil
Stator coil
Pulser coil
!
~
qj"fM/
30 Nm (3.0 m.kg, 22 ft.lb)
4-75
1 1'.1
ENG
ENG [ ,~[
YB344011
CD
"
~~
NOTE: _______________________
Fasten a safety wire to the timing chain to
prevent it from falling into the crankcase.
2. Apply:
-4-stroke engine oil
(onto journal and starter drives)
3. Install:
-Washer
-Wheel gear
CD
C2)
4. Install:
- Compression spring
- Starter clutch spring cap
-Dowel pin
CD
CD
5. Install:
-Woodruff key
-Rotor C2)
4-76
CD
C2)
I 1,.1
6. Install:
-Bolt
CD (rotor)
Bolt (rotor):
50 Nm (5.0 m.kg, 36 ftlb)
NOTE: _________________________
Tighten the bolt (rotor) while holding the rotor
with the rotor holder CZJ.
~ Rotor holder:
PIN. YS-01880, 90890-01701
?'-
7. Install:
-Starter idle gear 1
-Shaft CZJ
-Collar
- Dowel pins @
-Gasket @ (crankcase cover)
CD
8. Install:
- Crankcase cover
CD (left)
NOTE: _________________________
Tighten the bolts (crankcase cover) in a crisscross
pattern.
4-77
4-78
ENG
(2)
I \ ,. . 1
Q) O-ring
@ Cylinder gasket
(f)
@
Dowel
O-ring
Piston
Piston
Piston
Piston
pin
ring
pin clip
pin
4-79
ENG
1\,.1
CYLINDER HEAD
CD
@ Cylinder head
Bolt
~ Washer
Q) Spark plug
@ Tappet cover (intake)
@ O-ring
Bolt (oil check)
(j) Tappet cover (exhaust)
@
@
@
Dowel pin
Gromet
Cylinder head gasket
O-ring
Cylinder head side cover
~
\
4-80
ENG
1,.1
Gasket
(j)
Pin
Cam sprocket
Timing chain
Timing chain guide (exhaust)
SHAFT-TO-CAP CLEARANCE:
0.020-0.061 mm
(0.0008 - 0.0024 in)
4-81
ENG
YB344012
2. Install:
- Piston rings
NOTE: _________________________
Be sure to install ring so that manufactures marks
or numbers are located on the top side of the
rings.
307-026
3. Install:
-Pistons
- Piston pin
- Piston pin clips
CD
ell
NOTE: __________________________
-The arrow
on the piston must point to the
front of the engine.
- Before installing the piston pin clip, cover the
crankcase with a clean towel or rag so you will
not accidentally drop the piston pin clip and
material into the crankcase.
4. Position:
-Top ring
-2nd ring
Offset the piston ring end gaps as shown.
CD
Q)
@
4-82
ENG [ , . [
5. Install:
CD
- Dowel pins
-Gasket 0(cylinder)
-O-ring
6. Install:
- Cylinder
CD
NOTE: _________________________
Install the cylinder while compressing the piston
ring by the hand.
7. Install:
- Clutch cable holder
-Solts 0
CD
I~ Bolts~:
~
8. Install:
- Dowel pins
-Gromment 0
-Gasket (cylinder head)
-Timing chain guide
(exhaust)
CD
4-83
CD
10. Install:
-Bolts
Bolts CD - @ :
22 Nm (2.2 m.kg, 16 ftlb)
Bolt @' @ :
20 Nm (2.0 m.kg, 14 ftlb)
NOTE: __________________________
- Apply the 4-stroke engine oil onto the washers.
-Tighten the bolts starting with the lowest numbered one.
-The embossed numbers in the cylinder head
designate the tightening sequence.
11. Install:
-Cam sprocket
*****************************************
Installing steps:
Turn the crankshaft counterclockwise until the
is aligned with the stationary
TDC mark
pointer ~ .
Align the pin
on the camshaft with the stationary pointer @ on the cylinder head .
Fit the timing chain onto cam sprocket and install the cam sprocket on the camshaft.
CD
NOTE: _________________________
-When installing the cam sprocket, keep the timing chain as tense as possible on the exhaust
side.
- Align the mutch mark on the cam sprocket
with the stationary pointer @ on the cylinder
head.
- Align the pin
on the camshaft with the slot
in
the
cam
sprocket.
4-84 _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
1 1'.1
ENG
!1111'ljl ;:I
Do not turn the crankshaft during the camshafts installation. Damage or improper
valve timing will result.
I~
\Y~
(j).
*****************************************
12. Install:
eTiming chain tensioner
*****************************************
Installing steps:
While pressing the tensioner rod lightly with
fingers, use a thin screwdriver CD and wind the
tensioner rod up fully clockwise.
With the rod fully wound, install the gasket (2)
and the chain tensioner @' and tighten the
bolt @ to the specified torque.
,~.
~.
\Y~
*****************************************
4-85
ENG
I~.I
13. Check:
-Valve timing
Out of alignment~Adjust.
Refer to above steps 11 -12.
14. Check:
-Valve clearance
Out of specification ~ Adjust.
Refer to "VALVE CLEARANCE ADJUSTMENT" section in the CHAPTER 3.
15. Install:
-O-ring CD
- Cylinder head side cover ~
Bolt (cylinder head side cover):
7 Nm (0.7 m.kg, 5.1 ftlb)
16. Apply:
-4-stroke engine oil
(to the camshaft upper side)
Oil quantity:
17. Install:
-Tappet cover (intake) CD
-Tappet cover (exhaust) ~
Bolt (tappet cover):
10 Nm (1.0 m.kg, 7.2 ft.lb)
4-86
ENG
1'.1
18. Install:
-Timing plug
-Plug (center) ~
CD
19. Instal!:
-Intake manifold
CD
20. Install:
- Spark plug
CD
Spark plug:
17.5 Nm (1.75 m.kg, 12.5 ftlbl
21. Install:
-Oil strainer
-Compression spring ~
-O-ring @
CD
- Drain plug
Drain plug:
43 Nm (4.3 m.kg, 31 ft.lbl
YB244014
REMOUNTING ENGINE
When remounting the engine, reverse the removal
procedure. Note the following points.
4-87
ENG
1\.1
1. Install:
- Pivot shaft CD
-Mounting bolt ~ (front-upper)
-Mounting bolt
(rear-lower)
-Mounting bolts
(front-lower)
NOTE: __________________________
Install the all bolts and nuts first, and then tighten the bolts and nuts to specifications.
2. Connect:
-Spring CD
3. Install:
- Rear brake pedal ~
-Brake pedal shaft
-Washer @
-Circlip @
ENG
1'_1
4. Install:
-Compression spring
-Pin ([)
-Adjuster
5. Adjust:
-
6. Install:
- Drive chain CD (with drive sprocket)
-Sprocket holder (2)
-Bolts
Bolts:
10 Nm (1.0 m.kg. 7.2 ftlb)
7. Adjust:
- Drive chain slack
Refer to the "DRIVE CHAIN SLACK ADJUSTMENT" section in the CHAPTER 3.
Drive chain slack:
35-45 mm (1.38-1.n in)
8. Install:
-Crankcase cover 2
- Footrest (2) (left)
-Shift arm
CD
Bolt (footrest):
32 Nm (3.2 m.kg. 23 ft.lb)
Bolt (shift arm):
10 Nm (1.0 m.kg. 7.2 ft.lb)
4-89
ENG
I~.I
NOTE: __________________________
Install the shift arm @ and the shift rod
that they form a right angle .
@ so
9. Check :
-Shift pedal position
Check that the shift pedal is set to same as
the footrest top.
Not set-> Adjust .
10. Adjust:
" - Shift pedal position
*****************************************
Adjustment steps
Loosen the locknut
rod @.
G),
G)'
~ to the specified
Locknut:
10 Nm (1 .0 m.kg, 7.2 ft.lb)
*****************************************
11 . Connect:
-Wire earth lead G)
- Starter motor lead ~
(to the crankcase)
Refer to the "CABLE ROUTING" section in
the CHAPTER 2.
I~
4-90
Bolt:
7 Nm (0.7 m.kg, 5.1 ftlb)
ENG
1".1
12. Apply:
- Litium soap base grease
(on to the O-ring on starter motor)
13. Install:
-Starter motor
~
"
CD
14. Connect:
- Starter motor lead ~
(to starter motor and clamps)
15. Connect:
'-
16. Install:
-Horn
CD
17. Connect:
- Clutch cable
18. Adjust:
-Clutch cable free play
Refer to the "CLUTCH ADJUSTMENT"
section in the CHAPTER 3.
4-91
ENG
1,.1
Free play:
10-15 mm (0.39-0.59 in )
at clutch lever end
"
19. Connect:
- Carburetor
-Air vent hose ~ (Except for California)
CD
20 . Connect:
- Crankcase ventilation hose
21. Install :
- Exhaust pipe
CD
CD
22. Connect:
- Rear brake switch rod ~
Refer to the "CABLE ROUTING" section in
the CHAPTER 2.
23. Install:
-Muffler
- Protector ~
CD
Bolt (muffler!:
27 Nm (2.7 m.kg, 19 ftlb)
Bolt (protector):
7 Nm (0.7 m.kg, 5.1 ft.lb)
Use LOCTITE.
4-92
ENG
1,.1
24. Tighten:
Bolt
(exhaust pipe)
Bolt (l) (clamp)
CD
Bolt
10
Bolt
20
25. Install:
Canister
,
(exhaust pipe):
Nm (1.0 m.kg, 7.2 ftlb)
(clamp):
Nm (2.0 m.kg, 14 ftlb)
Bolt (canister):
10 Nm (1.0 m.kg, 7.2 ftlb)
26. Connect:
Battery negative lead
Refer to the "BATTERY INSPECTION"
section in the CHAPTER 3.
CD
27. Install:
CD
Engine guard
Refer to the "ENGINE OIL REPLACEMENT"
section in the CHAPTER 3.
Bolt (engine guard):
7 Nm (0.7 m.kg, 5.1 ftlb)
4-93
ENG
1 '
..
28. Fill:
-4-stroke engine oil
(to the crankcase)
Refer to the "ENGINE OIL REPLACEMENT
and OIL PRESSURE INSPECTION" section
in the CHAPTER 3.
Oil quantity:
Total amount
1.3 L (1.14 Imp'qt, 1.37 US.qt)
29. Install:
-Fuel tank
-Air scoops
-Seat
- Side covers
Refer to the "SEAT, FUEL TANK AND
COVER" section in the CHAPTER 3.
' 17.
O'~
30. Check:
- Engine idle speed
Refer to the "IDLING SPEED ADJUSTMENT" section in the CHAPTER 3.
~~
31. Check:
- Brake light operating timing and each light
operation.
Incorrect~ Adjust or repair.
4-94
CARBURETOR
ICARSI " I
CARBURETION
SPECIFICATIONS
CARBURETOR
CD
4BE10 (USA-Except
for California)
3RWOO (CDN)
4BEOO (USA-For
California)
Diaphragm cover
~ Diaphragm spring
ID MARK
(j)
(jJ)
@
(j3)
@
@
@l
~
~
-, ,-
;-_
p /
2 Nm
./1tr
' 0
1.2 Nm
10.12 m.kg, 0.9 ftlb)
n~'~~cr~, -'- / ~
U~ .~ ,
,...-------\.. .,@ @'"
'\ ",/
II
~~.
~
a
-----;~
2 Nm
(0.2 m.kg, 1.4 ftlb)
5-1
_ _ _ _ _ _ _ _ _ _ _C_A_R_B_U_R_ET_O_R_lcARSI "
SECTIONAL VIEW
SU TYPE CARBURETOR
The SU carburetor features a butterfly type throttle valve that is operated by moving the throttle
grip which in turn controls the piston valve by means of negative intake pressure.
The throttle valve controls the air/fuel mixture where at the same time the piston valve regulates
the venturi area by use of negative pressure. This keeps the velocity of the air/fuel mixture stream
more constant in supplying the engine with the necessary mixture at all times.
COASTING ENRICHER (purpose)
When the throttle valve is suddenly closed, the main fuel path is cut causing a lean mixture and
sometimes unstable idling. The coast enricher compensates for this lean mixture.
(Operation)
When the throttle valve is open, air is supplied by both pilot air jets (1 & 2). Negative pressure is
always present in the carburetor, however, when the throttle valve is open, negative pressure is
weaker than the force of the enricher valve spring, which keeps the enricher valve open and allows
air to be supplied by pilot air jet 2.
When the throttle valve is closed, negative pressure is increased which pulls the enricher valve close
and cuts off air supply from pilot air jet 2. Air intake supplied by only pilot air jet 1 provides an adequate mixture for stable idling and low speed performance.
CD
Coasting enricher
Valve spring
Pilot air jet 1
OPEN
[ill CLOSED
Enricher valve
r----
I8l
@ Piston valve
@ Throttle valve
(j) Enricher valve
T----,
I
I
I
I
I
I
I
I
I
I
IL _ _ _ _ _ _ _ _ -'
5-2
Air
c:i
Negative pressure ~
_ _ _ _ _ _ _ _ _ _ _C_A_R_B_U_RE_T_O_R_lcARBI
REMOVAL
1. Remove:
-Side covers
-Seat
-Air scoops
-Fuel tank
Refer to the "SEAT, FUEL TANK AND
COVER" section in the CHAPTER 3.
2. Drain:
- Fuel (float chamber)
Refer to the "ENGINE OVERHAULENGINE REMOVAL" section in the CHAPTER 4.
3. Loosen:
- Locknut
CD (throttle
cable)
4. Remove:
ClJ
- Locknut
(from cable adjust bolt)
-Throttle cable
(from throttle lever and
cable holder)
5. Loosen:
-Screws
CD
NOTE: _________________________
Move carburetor joint clamp
ClJ to the
6. Disconnect:
- Air vent hose CD
(Except for USA-California)
7. Remove:
-Carburetor assembly
8. Disconnect:
- Air vent hoses
- Over flow hose @
- Canister hose
(For USA-California)
5-3
ClJ
rear.
CARBURETOR
\CARBI' I
9. Remove:
- Starter cable CD
-Fuel hose ~
10. Disconnect:
- Starter plunger assembly
(from starter cable)
CD
DISASSEMBLY
NOTE: _________________________
1. Remove:
- Float chamber CD
-Pilot screw- ~ (Except for USA)
2. Remove:
-Float pin CD
-Float ~
- Needle valve
NOTE: _________________________
Remove the float pin in the arrow direction.
5-4
CARBURETOR
ICARsl. I
3. Remove:
-Main jet
-Pilot jet ~
-Screw @
-Valve seat @
CD
4. Remove:
-Cover assembly
-Spring ~
- Diaphragm @
-O-ring @
CD (coasting enricher)
5. Remove:
- Diaphragm cover
6. Remove :
- Diaphragm spring
- Diaphragm ~
-O-ring @
7. Remove :
- Diaphragm
-Ring ~
-Jet needle
-E-ring @
5-5
CD
@
CD
CD
_ _ _ _ _ _ _ _ _ _ _C_A_R_B_U_RE_T_O_R_\CARB[
8. Remove:
- Pilot air jet
CD
9. Remove:
-Needle jet
CD
NOTE:
Remove the needle jet towards the diaphragm
side.
INSPECTION
1. Inspect:
- Carburetor body
- Starter jet
- Float chamber
Cracks/ Damage-> Replace.
- Fuel passage
Contamination -> Clean.
NOTE: _________________________
CD
2. Inspect:
-Valve seat
- Needle valve ~
-O-ring @
Damage/Wear / Contamination -> Replace as
a set.
NOTE: _________________________
CD
5-6
ICARBI. I
CARBURETOR
3. Inspect:
eFloat
e Float arm
CD
Damage~
(2)
Replace.
4. Inspect:
eMain jet
e Needle jet (2)
epilot jet @
e Pilot air jet @
Wear / Damage ~ Replace.
Contamination -+ Blowout jets with compressed air.
CD
5. Inspect:
e Diaphragm
CD
Tears/Damage ~ Replace
diaphragm assembly.
e Piston valve (2)
Scratches/Wear / Damage~ Replace diaphragm assembly.
eJet needle @
Wear / Bend/ Damage~ Replace.
6. Inspect:
e Cover assembly
eO-ring (2)
Wear / Damage~ Replace.
e Diaphragm spring @
Damage~ Replace diaphragm assembly.
e Diaphragm @
Tears / Damage~ Replace.
CD
V'
7. Inspect:
eStarter plunger
Bends/Wear / Damage~ Replace.
-.
CD
eSpring
(2)
Damage~Replace.
5-7
_ _ _ _ _ _ _ _ _ _ _ _C_A_RBURETOR
ICARBI.I
8. Check:
e Free movement
Stick -> Replace.
Insert the piston valve into the carburetor
body, and check for free movement.
ASSEMBLY
Reverse the "DISASSEMBLY" procedures. Note
the following points.
l llllllll~
e
________
1. Install:
e Needle jet
CD
NOTE: _________________________
Align the cut end of the needle jet with the slot
on the body.
2. Install:
eRing
eJet needle
eE-ring
CD
(2)
NOTE: _________________________
Match the tab on tr.~ diaphragm assembly @ to
the matching recess in the carburetor body.
3. Install:
eO-ring
e Diaphragm spring (2)
e Diaphragm cover @
CD
5-8
CARBURETOR
ICARBI. I
4. Install:
-O-ring G)
- Diaphragm ~ (coasting enricher)
-Spring @
- Cover assembly @
NOTE: __________________________
Match the tab on the rubber diaphragm to the
matching recess in the carburetor body.
5. Install:
-Pilot screw G) (except for USA)
-Pilot jet ~
-Main jet @
-Valve seat @
- Needle valve
(with float)
Pilot jet:
1 Nm (0.1 m .kg, 0.7 ftlb)
Main jet:
1.8 Nm (0.18 m.kg, 1.3 ftlb)
Screw (valve seat):
1 Nm (0.1 m .kg, 0.7 ftlb)
6. Install:
- Float pin
G)
NOTE: _________________________
Install the float pin reverse to the arrow.
5-9
___________C_A_R_B_U_R_ET_O_R_lcARBI
7. Measure:
Float height
Out of specification --> Adjust.
*****************************************
CD
*****************************************
8. Install:
Float chamber
CD
9. Adjust:
Pilot screw
*****************************************
Adjustment steps:
Turn in the pilot screw until it is lightly seated .
Back out by the specified number of turns.
Pilot screw (turn out):
2 turns out
*****************************************
5-10
CARBURETOR
ICARsl' I
INSTALLATION
Reverse the "REMOVAL" procedures. Note the
following points.
1. Install:
-Starter cable G)
Refer to the "CABLE ROUTING" section in
the CHAPTER 2.
Starter plunger cap:
25 Nm (0.25 m.kg, 1.8 ftlb)
2. Connect:
- Over flow hose G)
- Air vent hoses
-Canister hose @ (For USA-California)
Refer to the "CABLE ROUTING" section in
the CHAPTER 2.
ClJ
3. Install:
- Carburetor assembly
'.#7~~
G)
4. Connect:
- Air vent hose
(Except for USA-California)
ClJ
5. Install:
- Throttle cable G)
Refer to the "CABLE ROUTING" section in
the CHAPTER 2.
Nut (throttle cable):
5 Nm (0.5 m.kg, 3.6 ft.lb)
5-11
CARBURETOR
ICARBI. I
6. Adjust:
-Throttle cable free play
Refer to the "THROTTLE CABLE FREE
PLAY ADJUSTMENT" section in the
CHAPTER 3.
Throttle cable free play:
3-5 mm (0.12-0.20 in)
7. Adjust:
-Idle speed
Refer to the "IDLE SPEED ADJUSTMENT"
section in the CHAPTER 3.
Engine idle speed:
1,300-1,500 r/min
Fuel level:
11.0-12.0 mm (0.43-0.47 in)
Below from the float chamber
mating surface (front)
5-12
CARBURETOR
7. Adjust:
-Fuel level
*****************************************
Adjustment steps:
Remove the carburetor.
Inspect the valve seat and needle valve.
If either is worn, replace them both.
If both are fine, adjust the float height by bending the float tang
on the float.
Recheck the fuel level.
CD
*****************************************
5-13
FRONT WHEEL
\CHASi #:Y0i
CHASSIS
FRONT WHEEL
CD Wheel axle
Maximum load*
(l Cotter pin
Washer
@ Collar
@ Dust cover
@ Oil seal
Q) Bearing
Spacer collar
Front wheel
Bearing
@ Gear unit (speedometer)
@ Washer
@ Nut
J Cable band
Disc cover
Front
Rear
Up to 90 kg
(198 Ib) load*
150 kPa
125 kPa
(1.25 kg/cm 2, (1.50 kg/cm 2,
18 psi)
21 psi)
150 kPa
175 kPa
(1.50 kg/cm2, (1.75 kg/cm 2,
25 psi)
21 psi)
175 kPa
150 kPa
High speed riding (1.50 kg/cm 2, (1.75 kg/cm 2,
25 psi)
21 psi)
*Load is the total weight of cargo, rider, passenger and accessories.
A
8
TIRE SIZE:
2.75-21-4PR
RIM SIZE:
1.6x21
WEAR LIMIT:
0.8 mm (0.03 in)
2 Nm
(0.2 mkg, 1.4 ftlb)
, 86202
6-1
FRONT WHEEL
ICHASI~(!) I
REMOVAL
WARNING
3. Remove:
-Cable band
CD
- Disc cover ~
- Speedometer cable
4. Remove:
CD
- Cotter pin
-Nut ~
-Wheel axle @
- Front wheel
NOTE: _________________________
Do not depress the brake lever when the wheel
is off the motorcycle otherwise the brake pads
will be forced shut.
5. Remove:
-Collar
- Dust cover ~
-Gear unit (speedometer)
CD
!Al
Right side
CD
6-2
FRONT WHEEL
ICHASI~GlI
INSPECTION
1. Eliminate any corrosion from parts.
2. Inspect:
-Wheel axle
Roll the axle on a flat surface.
Bends~ Replace.
,.(7'
--.-----------~J!f ~
A WARNING
Do not attempt to straighten a bent axle.
3. Inspect:
-Tire
Wear I Damage~ Replace.
Refer to the "TIRE INSPECTION" section
in the CHAPTER 3.
-Wheel
Bendsl Damage~ Replace.
Refer to the "WHEEL INSPECTION" section in the CHAPTER 3.
4. Check:
-Spoke(s)
Bendl Damage~ Replace.
Loose spoke(s) ~ Retighten.
Turn the wheel and tap the spokes with a
screw driver.
NOTE: __________________________
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
340005
5. Tighten:
- Loose spokes
Nipple:
2 Nm (0.2 m.kg, 1.4 ftlb)
NOTE: _________________________
Check the wheel runout after tightening spoke.
6. Measure:
-Wheel runout
Out of specification~Check the wheel and
bearing play.
Rim runout limits:
Vertical
2.0 mm (0.08 in)
Lateral
2.0 mm (0.08 in)
CD:
:
340002
6-3
ICHASI ~ I
FRONT WHEEL
A WARNING
-After mounting a tire, ride conservatively
to allow proper tire to rim seating. Failure
to do so may cause an accident resulting
in motorcycle damage and possible operator injury.
-After a tire repair or replacement, be sure
to torque tighten the valve stem locknut
to specification.
CD
341-009
7. Check:
-Wheel bearings
Abnormal noise/Turn roughly / Free
Replace.
-Oil seal (2)
Wear / Damage~ Replace.
CD
Radial Vertical
IAI
play~
Free play
*****************************************
(2)
6-4
FRONT WHEEL
.illll'.II!~ii
ICHASI ~ I
________
8. Inspect:
-Gear unit case
- Driven gear C2)
-Washer
-Meter gear @
- Meter clutch @
-Washer
CD
(speedometer)
- Circlip (j)
Wear / Cracks/ Damage--> Replace gear unit.
INSTALLATION
Reverse the "Removal" procedure.
Note the following points.
1. Lubricate:
-Wheel axle
-Oil seal (lip) C2)
-Bearings
-Drive @/Driven gear @ (speedometer)
CD
2. Install:
- Gear unit assembly
NOTE: _________________________
CD
6-5
FRONT WHEEL
ICHAsl #::rei
3. Install:
-Collar CD
- Dust
cover ~
NOTE:
________________________
_
Install the oil seal taking care not to damage or
reverse the lips.
4. Install:
- Front wheel assembly
NOTE:
_________________________
Be sure the boss on the outer fork tube CD correctly engages with the locating slot on the gear
unit assembly ~ .
5. Install :
-Wheel axle CD
-Washer ~
-Nut @ (wheel axle)
6. Tighten:
-Nut
@ (wheel axle)
Nut (wheel axle):
85 Nm (8.5 m.kg, 61 ftlb)
NOTE: ________________________
Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the
wheel axle cotter pin hole, align groove to hole
by tightening up on the axle nut.
7. Install:
pin CD
- Cotter
NOTE:
________________________
_
Bend the ends of the cotter pin as illustration .
j\WARNING
Always use a new cotter pin.
6-6
FRONT WHEEL
8. Install:
- Disc cover
-Speedometer cable
- Cable band @
ICHASI r#:Yel
CD
l llliIII!
(2)
---------------------
6-7
FRONT BRAKE
ICHASI r#Y01
FRONT BRAKE
CD
(g)
@
@
@
@
@
@
Caliper bracket
Brake pads
Ring (dust boot)
Dust boot
Piston seal
Piston
Brake disc
Cable band
1.5 Nm
(0.15 m.kg, 1.1 ftlb)
6-8
FRONT BRAKE
ICHAsl #:rei
A WARNING
Securely support the motorcycle there is no
danger of falling over.
1. Remove:
-Cable band
- Retaining bolt ~
CD
2. Remove:
- Caliper body
- Brake pads ~
- Pad spring @
CD
NOTE: _________________________
Remove the caliper body by lifting it up to the arrow direction.
6-9
ICHASI #Y01
--~-
-----------,
-.=--+-
FRONT BRAKE
NOTE: __________________________
I~
Wear limit
0.8 mm (0.03 in)
3. Inspection:
Caliper bracket
Caliper body ~
Cracks/ Oamage--+ Replace caliper assembly.
Rubber boot
Wear/ Cracks/ Damage--+ Replace.
CD
4. Lubricate:
CD
Guide pin
Slide collar ~
NOTE: _________________________
Place the rubber boot securely in the groove
of slide collar when installing the slide collar.
5. Install:
Pad springs
CD
NOTE: _________________________
Place the projections ~ securely in the groove
of caliper bracket when installing the pad
springs.
6-10
FRONT BRAKE
6. Install:
Brake pads
ICHASI~
CD
NOTE: __________________________
Be sure to position the pad so that its round side
faces backward.
*****************************************
Installation steps:
Connect the clear plastic tube
tightly to the
caliper bleedscrew. Then, place the other end
of this hose into an open container.
Loosen the caliper bleed screw and push the
piston into the caliper by your finger.
Tighten the caliper bleed screw.
CD
"
~~
*****************************************
7. Install:
Caliper body
Retaining bolts
Cable band
CD
C2)
Retaining bolt:
23 Nm (2.3 m.kg, 17 ftlb)
NOTE: __________________________
Place the rubber boot @ securely in the groove
of guide pin when installing the caliper body.
A WARNING
Proper hose routing is essential to insure safe
motorcycle operation.
Refer to the "CABLE ROUTING" section in
the CHAPTER 2.
6-11
FRONT BRAKE
(0
8. Inspect:
- Brake fluid level
Refer to the "BRAKE FLUID INSPECTION"
section in the CHAPTER 3.
c:>\
~owER._l_G)
ICHASi ris01
l,-------,
9. Check:
- Brake lever operation
A softy or spongy filling->Bleed brake
system.
Refer to the" AIR BLEEDING" section in the
CHAPTER 3.
CALIPER DISASSEMBLY
NOTE: _________________________
A WARNING
Securely support the motorcycle there is no
danger of falling over.
1. Remove:
-Bolt G) (brake hose holder)
- Cable holder (Z)
2. Disconnect:
- Brake hose
(from
3. Loosen:
-Union bolt
@
NOTE: ________________________
_
Loosen slightly so that brake fluid does not leak
out.
4. Remove:
- Retaining bolt
6-12
FRONT BRAKE
ICHASI~
5. Remove:
- Caliper body
-Brake pads
- Pad springs
Refer to the "BRAKE PAD REPLACEMENT" section.
6. Remove:
- Caliper bracket
G)
7. Remove:
-Union bolt G)
- Copper washers (2)
NOTE: _________________________
Place the container under the caliper to catch the
standing brake fluid.
8. Remove:
-Piston G)
*****************************************
Removal steps:
Blow compressed air into the tube joint opening to force out the piston from the caliper
body.
A WARNING
-Never try to pry out the piston.
-Cover the piston with a rag. Use care so
that piston does not cause injury as it is expelled from the cylinder.
*****************************************
6-13
FRONT BRAKE
ICHASI r#:Y01
9. Remove:
- Ring CD (dust boot)
-Dust boot ~
- Piston seal
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Remove:
-Mirror CD (right)
- Brake lever cover ~
-Nut
(brake lever)
- Bolt @ (brake lever)
2. Remove:
- Brake lever CD
- Return spring ~ (brake lever)
- Brake switch
NOTE: __________________________
Remove the brake switch by pushing up the stopper with a thin screwdriver as shown.
6-14
FRONT BRAKE
3. Loosen:
-Union bolt
ICHASI rff:y01
G)
NOTE: __________________________
Loosen slightly so that brake fluid does not leak
out.
4. Remove:
- Master cylinder
-Union bolt ~
- Copper washer
G)
NOTE: __________________________
Place a container under the master cylinder to
catch the standing brake fluid.
5. Remove:
- Master cylinder cap G)
- Diaphragm ~
-Plate
-Rubber boot
-Circiip
- Master cylinder kit
NOTE: __________________________
- Remove the circiip using circiip pliers (j).
- Place a container under the master cylinder to
catch the standing brake fluid.
6-15
FRONT BRAKE
ICHASI ~ I
As required
Piston seal.
dust seal
Brake hoses
Brake fluid
A WARNING
All internal parts should be cleaned in new
brake fluid only. Do not use solvents will
cause seals to swell and distort.
1. Inspect:
- Caliper cylinder G)
Wear/Scratches-> Replace caliper assembly.
- Caliper piston ~
Scratches/ Rust/Wear-> Replace caliper assembly.
A WARNING
Replace the piston seal and dust boot
whenever a caliper is disassembled.
2. Inspect:
-Caliper bracket G)
Cracks/ Damage-> Replace brake caliper assembly.
- Caliper body ~
Cracks/Damage-> Replace brake caliper assembly.
- Rubber boots @
Cracks/Wear / Damage-> Replace.
-Oil delivery passage (caliper body)
Blowout with compressed air.
6-16
FRONT BRAKE
\CHAS\ #Y0\
3. Inspect:
Master cylinder CD
Wear / Scratches---+ Replace master cylinder
assembly.
Master cylinder body CZ)
Cracks / Damage---+ Replace .
Oil delivery passage (master cylinder body)
Blowout with compressed air.
4. Inspect:
Master cylinder kit CD
Scratches / Wear / Damage---+Replace as a
set.
5. Inspect:
Diaphragm CD
Wear / Damage---+ Replace .
6. Inspect:
Brake hoses CD
Cracks / Wear / Damage---+ Replace .
7. Measure:
Brake pad thickness
Out of specification---+ Replace .
- - -I:D:c:. : .-.:-:---. :~
--1 ~!
9L..-_ _ _ _ _---IP f
I~
.-1-1
NOTE: _________________________
FRONT BRAKE
ICHASI AI
8. Inspect:
- Brake disc
Galling / Damage-+ Replace .
CD
9. Measure:
- Brake disc deflection
Out of specification-+lnspect wheel runout.
If wheel runout is in good condition, replace
the brake disc(s).
Maximum deflection:
0.3 mm (0.01 in)
CD
Dial gauge
CD
Micrometer
NOTE: __________________________
Tighten the bolts (brake disc) in stage using a
crisscross pattern.
CALIPER ASSEMBLY
A WARNING
-All internal parts should be cleaned in new
brake fluid only.
-Internal parts should be lubricated with
brake fluid when installed.
Brake fluid:
DOT #4 or DOT #3
6-18
FRONT BRAKE
ICHASI r#:Yel
1. Install:
- Piston seal G)
-Piston (2)
-Dust boot
-Ring @ (dust boot)
NOTE: _________________________
First, assemble the piston seal, then assemble the
piston. Stop when this is about half finished and
attach the dust boot. Then, while moving the
piston into position, attach the dust boot to the
main unit as well. Attach the ring (dust boot) last.
2. Install:
-Caliper bracket
G)
3. Install:
-Pad springs
-Brake pads
- Retaining bolt
Refer to the "BRAKE PAD REPLACEMENT" section.
NOTE: _________________________
Place the rubber boot securely in the groove of
guide pin when installing the caliper body.
6-19
FRONT BRAKE
ICHASI r!s01
Retaining bolt:
23 Nm (2.3 m.kg, 17 ftlb)
4. Install:
- Copper washers
-Brake hose ~
-Union bolt
CD
"
~~
Union bolt:
27 Nm (2.7 m.kg, 19 ftlb)
A WARNING
- Proper hose routing is essential to insure
safe motorcycle operation.
Refer to the "CABLE ROUTING" section in
the CHAPTER 2.
-Always use new copper washers.
5. Connect:
- Brake hose
CD
6. Install:
- Bolt ~ (brake hose holder)
- Cable holder
6-20
WARNING
7. Fill:
- Brake fluid
,ifh
'V
A WARNING
- Use only the designated quality brake fluid:
otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
-Refill with the same type of brake fluid;
mixing fluids may result in a harmful chemical reaction and lead to poor performance.
- Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
8. Air bleed:
- Brake system
Refer to the "AIR BLEEDING" section in the
CHAPTER 3.
6-21
FRONT BRAKE
/0
ICHASj ~ I
9. Inspect:
- Brake fluid level
Fluid level is under "LOWER" level line
~Fill up .
Refer to the "BRAKE FLUID INSPECTION"
section in the CHAPTER 3.
e>\
CD
~OWER._~
l
10. Install:
- Diaphragm
- Master cylinder cap
-Screws
CD
(2)
~~
& WARNING
-All internal parts should be cleaned in new
brake fluid only.
-Internal parts should be lubricated with
brake fluid when installed.
Brake fluid:
DOT #4 or DOT #3
1. Install:
- Master cylinder kit
-Circlip (2)
-Rubber boot
-Plate @
NOTE: _________________________
CD
6-22
@. push
it in securely
FRONT BRAKE
ICHASI~GlI
2. Install:
-Master
cylinder CD
NOTE:
________________________
__
-Install the master cylinder bracket with the "UP"
mark facing upward.
-Tighten first the upper bolt then the lower bolt.
~
7~
3. Install:
- Copper washers
-Brake hose
-Union bolt @
CD
Union bolt:
27 Nm (2.7 m.kg, 19 ft.lb)
NOTE: _________________________
Install the brake hose as shown.
A WARNING
-Proper hose routing is essential to insure
safe motorcycle operation.
Refer to the "CABLE ROUTING" section in
the CHAPTER 2.
-Always use new copper washers.
4. Install:
- Brake switch CD
-Spring
- Brake lever @
-Brake lever cover @
-Mirror (right) @
NOTE: _________________________
6-23
FRONT BRAKE
ICHASI ~ I
5. Fill:
-Brake fluid
Recommended brake fluid:
DOT #4 or DOT #3
A WARNING
- Use only the designated quality brake fluid:
otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
- Refill with the same type of brake fluid;
mixing fluids may result in a harmful chemical reaction and lead to poor performance.
-Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
6. Air bleed:
- Brake system
Refer to the "AIR BLEEDING" section in the
CHAPTER 3.
6-24
FRONT BRAKE
ICHASI#:'r01
7. Inspect:
- Brake fluid level
Fluid level is under "LOWER" ~evel line
-4 Fill up.
Refer to the "BRAKE FLUID IKisPECTION"
section in the CHAPTER 3.
CD
r ~OWER.k
l,---------./
8. Install:
CD
- Diaphragm
-Master cylinder cap ~
-Screws @
Screw (master cylinder cap):
1.5 Nm (0.15 m.kg, 1.1 ft.lb)
6-25
__________________________
R_EA_R__W_H_E_E__
L
REAR WHEEL
CD
CV
Camshaft lever
Wear indicator plate
Q) Pin
@ Adjuster
Brake shoe plate
Camshaft
(f) Brake shoe
Brake shoe spring
Bearing
Spacer flange
(jJ) Spacer
Brake rod
@ Compression spring
@ Collar
@ Rear wheel
Bearing
Wheel axle
ICHASI~01
Front
125 kPa
(1.25 kg/cm 2,
18 psi)
Rear
150 kPa
(1.50 kg/cm 2 ,
21 psi)
150 kPa
(1.50 kg/cm 2 ,
21 psi)
150 kPa
(1.50 kg/cm 2 ,
21 psi)
175 kPa
(1.75 kg/cm 2 ,
25 psi)
175 kPa
(1.75 kg/cm 2 ,
25 psi)
Up to 90 kg
(198 Ib) load*
@ Oil seal
@ Dust collar
@> Cotter pin
TIRE SIZE:
120/S0-1S-62P
RIM SIZE:
2.15x 1S
WEAR LIMIT:
O.S mm (0.03 in)
DRIVE CHAIN SLACK:
35-45 mm 11.38-1.n in)
6-26
_________________________R_E_A_R_W__H_EE_L_lcHAS~1
REMOVAL
Rear wheel
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Place the motorcycle 'on a level place.
2. Elevate the rea r wheel by placing a suitable
stand under the frame and engine .
3. Remove:
- Cotter pin CD
- Axle nut (2)
-Chain puller @
-Adjuster @
-Compression spring
-Pin
4. Remove:
-Wheel axle CD
-Chain puller (2) (left)
-Collar @
NOTE: __________________________
When removing the wheel axle, the collar
fall off. Take care not to lose it.
5. Remove:
- Rear wheel CD
- Brake shoe plate
@ will
(2)
NOTE: __________________________
Before removing the rear wheel , push the wheel
forward and remove the drive chain.
6. Remove:
- Dust collar
6-27
CD
__________________________
R_EA
__
R_W_H_E_E__
l
ICHASI~01
Rear brake
1. Remove:
- Brake shoe
- Brake shoe spring (2)
NOTE: _________________________
CD
2. Remove:
- Camshaft lever
-Wear indicator plate
-Camshaft
CD
(2)
NOTE: _________________________
CD,
INSPECTION
1. Inspect:
-Wheel axle
-Tire
-Wheel
Refer to the "FRONT WHEEL-INSPECTION" section_
2. Check:
-Spoke(s)
Refer to the "FRONT WHEEL-INSPECTION" section.
3. Measure:
-Wheel runout
Refer to the "FRONT WHEEL-INSPECTION" section.
6-28
_________________________R_EA_R__W_H_E_El_lcHASI~01
4. Check:
-Wheel bearings
-Oil seals
Refer to the "FRONT WHEEL-INSPECTION" section.
5. Inspect:
- Brake shoe plate CD
-Pivot pin ~
-Camshaft @
Cracks/ Oamage-+ Replace.
6. Inspect:
- Brake shoe CD
-Brake shoe spring ~
Cracks/ Oamage-+ Replace as a set.
NOTE: _________________________
When replacing the brake shoes, replace the
brake shoe springs at the same time.
7. Inspect:
- Brake shoe lining surface
Glazed areas-+ Remove.
Use a coarse sand paper.
NOTE: _________________________
After using the sand paper, clean of the polished
particles with cloth.
8. Measure:
-Brake shoe lining thickness
Out of specification -+ Replace.
CD
Measuring points
NOTE: _________________________
Replace the brake shoes as a set if either is found
to be worn to the wear limit.
6-29
_________________________
RE_A_R_W
__H_E_EL_cHASI~1
Brake lining thickness:
4 mm (0.16 in)
Wear limit:
2 mm (0.08 in)
9. Inspect:
Brake drum inner surface
Oil l Scratches-> Replace.
Oil
Scratches
10. Measure:
Brake drum inside diameter
Out of specification-> Replace.
ASSEMBLY
Rear brake
Reverse the "REMOVAL" procedure.
Note the following points.
1. Lubricate:
Camshaft G)
Pivot pin CZ)
riI
6-30
________________________R_E_A_R_W
__H_E_EL_lcHAS~1
2. Install:
- Brake shoe CD
- Brake shoe spring ~
NOTE: _________________________
3. Install:
-Wear indicator plate
CD
NOTE: __________________________
4. Install:
- Camshaft lever
CD
~
6-31
_________________________R_E_A_R_W__H_EE_L_lcHAS~1
2. Adjust:
- Drive chain slack
Drive chain slack:
35-45 mm (1.38-1.n in)
Refer to the " DRIVE CHAIN SLACK ADJUSTMENT" section in the CHAPTER 3.
3. Tighten :
-Axle nut
Axle nut:
85 Nm (8 .5 mokg, 61 ftolb)
NOTE: _________________________
Do not loosen the axle nut after torque tightening.
If the axle nut groove is not aligned with the wheel
axle cotter pin hole, align groove to hole by tightening up on the axle nut.
4. Install :
pin CD
Cotter
NOTE:
________________________
_
Bend the ends of the cotter pin as illustration.
A WARNING
Always use a new cotter pin.
349000
~--------------------------------~
5. Adjust:
- Brake pedal free play
Refer to the " REAR BRAKE ADJUSTMENT" section in the CHAPTER 3.
Brake pedal free play:
20 - 30 mm (0.8-1.2 in)
A WARNING
After adjusting the brake pedal free play,
brake light switch should be adjusted.
6-32
_________________________F_RO_N_T__FO_R_K_lcHASI~1
FRONT FORK
CD
<V
Piston ring
@ Damper rod
(j3) Rebound spring
Inner fork tube
Oil lock piece
@ Dust seal
@ Oil seal stopper ring
@ Oil seal
@ Seal spacer
@ Guide bush
@ Outer fork tube
@ Front fork (left)
[II Cut the end of the band.
FORK SPRING:
MINIMUM FREE
B
LENGTH:
588.8 mm (23.18 in)
23 Nm
(2.3 m.kg, 17 ftlb)
".:?F~"~~
20 Nm
(2.0 m.kg, 14 ftlb)
OIL LEVEL:
147 mm (5.8 in)
C From top of inner fork
tube fully compression
without spring
zyv
6-33
_________________________FR_O_N_T__FO_R_K_cHASI~1
REMOVAL
A WARNING
Support the motorcycle securely so there is
no danger of it falling over.
4. Remove:
-Holder CD (brake hose and meter cable)
-Bolt ~ (brake caliper)
5. Remove:
- Air valve cap
CD
NOTE: _________________________
Bleed sealed air from the air valve ~ with the
air-sealed forks .
6. Loosen:
-Pinch bolts CD (handlebar crown)
-Pinch bolts ~ (lower bracket)
A WARNING
Support the fork before loosening the pinch
bolt.
6-34
FO_R_K_cHAS~01
_________________________
FR_O_N_T__
7. Remove:
Front fork
CD
DISASSEMBLY
1. Remove:
Fork boot
CD
2. Remove:
CD
Stopper ring
Spring seat (2)
Fork spring @
NOTE: _________________________
Depress the spring seat and remove the stopper
ring.
3. Drain:
.Fork oil
4. Remove:
Dust seal
CD
NOTE: _________________________
Use a screwdriver, and be careful not to scratch
the outer fork tube.
6-35
_ _ _ _ _ _ _ _ _ _ _ _ _F_R_O_N_T_F_O_R_K_lcHASJ
5. Remove:
- Retaining clip
CD
NOTE: _________________________
Use a thin screwdriver, and be careful not to
scratch the inner fork tube.
6. Remove:
- Bolt
(damper rod)
-Washer CZ)
CD
NOTE: _________________________
Hold the damper rod to loosen the bolt (damper
rod) by the T-handle
and holder @.
T-handle:
YM-01326
90890-01326
Holder:
YM-01300-1
90890-01294
7. Remove:
- Damper rod
-Rebound spring
CD
6-36
CZ)
_________________________F_RO_N_T__FO_R_K_cHAS[~01
8. Remove:
-Inner fork tube
*****************************************
Removal steps:
Hold the fork leg horizontally.
Clamp the caliper mounting boss of the outer
fork tube securely in a vise with soft jaws.
Pull out the inner fork tube from the outer fork
tube by forcefully, but carefully, with drawing
the inner fork tube.
9. Remove:
-Oil seal
- Seal spacer @
-Guide bush
-Oil lock pieces
CD
6-37
_________________________FR_O_N_T__
FO_R_K_cHAS~1
INSPECTION
1. Inspect:
-Inner fork tube G)
-Outer fork tube (2)
Scratches/ Bends/ Damage~ Replace.
A WARNING
Do not attempt to straighten a bent inner
fork tube as this may dangerously weaken
the tube.
2_ Measure:
- Fork spring free length
Out of specification ~ Replace.
Fork spring free length:
594.7 mm (23.41 in)
Minimum free length:
588.8 mm (23.18 in)
342-018
3. Inspect:
- Damper rod G)
Wear / Bends/ Damage~ Replace.
Contamination ~ Blowout all oil passages
with compressed air.
- Piston ring (2)
Wear/Cracks/ Damage~ Replace.
A WARNING
Do not attempt to straighten a bent damper
rod as this may dangerously weaken the rod.
6-38
_________________________F_RO_N_T__FO_R_K_cHAS~1
4. Inspect:
- Rebound spring G)
Cracks / Damage~ Replace.
5. Inspect:
-Oil lock piece G)
-a-ring ~
- Air valve and spring seat
Damage~Replace.
ASSEMBLY
Reverse the "DISASSEMBLY" procedure. Note
the following points.
NOTE: _________________________
-In front fork reassembly, be sure to use following new parts.
*Guide bush
*Oil seal
*Dust seal
- Make sure all components are clean before reassembly.
1. Install:
- Damper rod
G)
6-39
_________________________F_RO_N_T__FO_R_K_lcHASI~01
2. Install:
- Oil lock piece
(to damper rod 0)
3. Lubricate:
-Inner fork tube (outer surface)
CD
4. Install:
-Inner fork tube
(to outer fork tube @)
5. Tighten:
- Bolt (damper rod)
Use the T-handle CD and holder
the damper rod.
T-handle:
YM-01326
90890-01326
Holder:
YM-01300-1
90890-01294
6. Lubricate:
-Inner fork tube (outer surface)
7. Install:
-Guide bush
- Seal spacer
6-40
CD
to lock
FO_R_K_cHAS~01
_________________________FR_O_N_T__
8. Install:
-Oil seal
Use the fork seal driver weight
ter @.
CD
NOTE: _________________________
Before installing the oil seal, apply the lithium soap
base grease onto the oil seal lips.
9. Install:
-Oil seal stopper ring
CD
NOTE: _________________________
CD
Q) Oil seal
6-41
_________________________F_R_O_N_T_F_O_R_K_lcHAS~01
10. Install:
Dust seal CD
Use the fork seal driver weight ~ and adapter @.
Fork seal driver weight:
YM-33963
90890-01367
Adapter
36 mm (1.42 in):
YM-OB010
90B90-01370
11. Fill:
- Front fork
Each fork:
355 cm 3 (12.5 Imp oz, 12.0 US oz)
Fork oil 10W or equivalent
After filling, slowly pump the
fork up and down to distribute oil.
Oil level @:
147 mm (5.B in)
From the top of inner fork tube
fullY' compressed without
spring.
CD
12. Install:
-Fork spring CD
- Spring seat ~
- Stopper ring @
6-42
_________________________F_R_O_N_T_F_O_R_K_cHASI~01
NOTE: _________________________
II
III~
@Iii~
... Front
13. Install:
- Fork boot
-Clamp ~
-Band @
CD
(left)
NOTE: _________________________
-Install the clamp and the band as shown.
-Cut the end of the band @.
A WARNING
Always use a new band.
INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Install:
- Front fork
Temporary tighten the pinch bolts.
NOTE: _________________________
Position the inner fork tube end in such a way
that it is flush
with the top of the handle
crown.
6-43
_________________________F_RO_N_T__FO_R_K_lcHAS~1
2. Tighten:
-Pinch bolts
(lower bracket)
- Pinch bolts (2) (handlebar crown)
- Air valve cap
CD
CD
(brake caliper)
(2) (brake hose)
A WARNING
Proper hose routing is essential to insure safe
motorcycle operation. Refer to the "CABLE
ROUTING" section in the CHAPTER 2.
4. Install:
- Front wheel
"
~~
6-44
\CHASj rff;::y0\
_..------\
}>\~\
\..---
. ~~
Ir;
I~~
~\/ ~ ~
. ~123 Nm 12.3 mokg.'7ftolbll
~-/~~
1 ~~ ~
111\
000.JJ;
0.
~ @l
.@
., -; @
~~----'
7 Nm
(0.7 m.kg. 5.1 ft.lb)
Aj TIGHTENING STEPS:
-Tighten ring nut.
38 Nm (3.8 m.kg. 27 ftlb)
-Loosen it one turn.
-Retighten it.
5.5 Nm (0.55 m kg. 4.0 ttlb)
8 Nm
(0.8 m.kg. 5.8 ftlb)
6-45
ICHASI~01
REMOVAL
Handlebar
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Place the motorcycle on a level place.
2. Disconnect:
-Sand CD
3. Remove:
- Master cylinder ~
4. Remove:
- Handlebar switch
5. Loosen:
-Screw
CD
CD (throttle
(right)
grip)
6. Disconnect:
-Sand CD
7. Loosen :
-Locknut ~ (clutch cable)
-Adjuster (clutch cable)
8. Remove:
-Clutch cable @
6-46
ICHASI~
9. Remove:
-Clutch lever holder
- Handlebar switch ~ (left)
CD
10. Remove:
-"CHOKE" knob
-Handlebar ~
-Throttle grip
-Collar
CD
Steering head
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
6-47
ICHASI ~ I
meter cable)
- Front fender ~
7. Remove:
- Front fork
Refer to the "FRONT FORK-REMOVAL"
section.
8. Remove:
- Holder
9. Disconnect:
-Main switch coupler
brake hose)
CD
NOTE: _________________________
After removing the couplers, put the main switch
leads outside taking care not to get entangled.
10. Remove:
-Solt
(headlight stay)
CD
11. Disconnect:
-Clip
(left)
- Flange collar ~
-Clip
- Flange collar @
CD
6-48
ICHASI ~ I
G)
NOTE: _________________________
When removing the meter assembly, the rubber
washer will falloff. Take care not to lose the rubber washer.
13. Remove:
- Handlebar crown G)
-Ring nut ~
- Lower bracket
- Ball race cover @
-Ball race (upper)
-Balls
NOTE: _________________________
@.
Ring nut wrench:
6-49
ICHASibel
A WARNING
Support the lower bracket
not fall down.
so that it may
YB275002
INSPECTION
1. Inspect:
- Handlebar
CD
Bends/Cracks/Damage~ Replace.
A WARNING
Do not attempt to straighten a bent h~ndle
bar as this may dangerously weaken the handlebar.
*****************************************
Replacement steps:
Remove the handlebar grip.
Apply a light coat of an adhesive for rubber on
the left new handlebar end.
Install the handlebar grip.
NOTE: _________________________
Wipe off excess adhesive with a clean rag.
WARNING
2. Inspect:
-Ball race (upper)
-Balls CZJ
-Ball race (lower)
CD
Wear/Pitting/Damage~
6-50
Replace as a set.
ICHASI rffs01
3. Inspect:
- Bearing race @ (lower)
Wear / Pitting/ Damage-> Replace as a set.
- Bearing race
(upper)
Wear / Pitting/ Damage-> Replace as a set.
*****************************************
Replacement steps:
Remove the bearing races from the slot on the
steering head pipe using a long rod
and
hammer as shown.
CD
4. Inspect:
- Handlebar crown
- Lower bracket ~
Cracks/ Damage-> Replace.
- Steering stem
Bends/ Damage-> Replace lower bracket assembly.
CD
A WARNING
Do not attempt to straighten a bent steering stem as this may dangerously weaken
the steering stem.
6-51
ICHASI~ I
INSTALLATION
Handlebar
Reverse the "REMOVAL" procedure.
Note the following points .
1. Lubricate:
-Handlebar
I~
NOTE: __________________________
Before installing the throttle grip onto the handlebar, apply a light coat of lithium soap base
grease onto the handlebar end.
-:;. -::-.:-/
2. Install:
-Collar
-Throttle grip (2)
- Handlebar @
-"CHOKE" knob
CD
Bolt (handlebar):
15 Nm (1.5 m.kg, 11 ftlb)
NOTE: __________________________
CD
NOTE: __________________________
The upper handlebar holder should be installed
with the punch mark
forward .
CD
() Forward
i il lllllll);; ________
354 01~
\CHAS\ #:Y0\
3. Install:
- Handlebar switch (left)
- Clutch lever holder
-Clutch cable
NOTE: __________________________
Apply a light coat of lithium soap base grease onto
the clutch cable end.
4. Connect:
-Bands
5. Install:
-Throttle grip
-Handlebar switch (right)
NOTE: __________________________
When installing the handlebar switch (right) make
sure its projection fits into the hole as shown.
6. Install:
-Brake master cylinder
NOTE: __________________________
CD
A WARNING
Proper hose routing is essential to insure safe
motorcycle operation. Refer to the "CABLE
ROUTING" section in the CHAPTER 2.
7. Connect:
-Bands (Z)
6-53
ICHASI~
8. Adjust:
- Clutch cable free play
Free play:
10-15 mm (0.4-0.6 in)
at lever end
Refer to the "CLUTCH ADJUSTMENT"
section in the CHAPTER 3.
Steering head
Reverse the "REMOVAL" procedure.
Note the following points.
1. Lubricate:
- Bearing (upper and lower)
-Ball races
2. Install:
-Balls
G)
NOTE: _________________________
Apply grease to the ball race (lower) liberally and
install the balls (22 pieces).
3. Tighten:
-Ring nut
G)
*****************************************
Tightening steps:
Tighten the ring nut using the ring nut wrench
(2).
Ring nut wrench:
P / N. Y U -33975, 90890-01403
6-54
ICHAsirff:y-el
NOTE: _________________________
Set the torque wrench to the ring nut wrench so
that they form a right angle.
' ./.7.
O'~
Turn the lower bracket to the left and right making sure there is no binding and then loosen the
ring nut one turn .
Retighten the ring nut using the ring nut
wrench.
A WARNING
Avoid over-tightening.
NOTE: __________________________
Check the steering head by turning the steering
from lock to lock, after adjusting steering head.
If steering is binded, loosen the ring nut but not
to the extent of free play in bearing.
If steering is loosened, repeat the adjustment
steps.
*****************************************
4. Install:
Handlebar crown
CD
NOTE: __________________________
Temporary tighten the steering fitting bolt
6-55
(2).
[CHAS[ ~ [
5. Install:
- Rubber washers CD
- Meter assembly (2)
- Headlight assembly
- Bolt @ (headlight stay)
- Flange collar
-Clip
-Bolt Q) (holder)
Bolt @
7 Nm
Bolt Q)
7 Nm
(headlight stay):
(0.7 m.kg, 5.1 ftlb)
(holder):
(0.7 m.kg, 5.1 ftlb)
WARNING
6. Connect:
- Main switch coupler CD
Refer to the "CABLE ROUTING" section in
the CHAPTER 2.
7. Install:
-Front fork
Refer to the "FRONT FORK-INSTALLATION" section.
NOTE: _________________________
Temporary tighten the pinch bolts.
6-56
ICHASI~
8. Tighten:
-Steering fitting bolt
CD
9. Tighten:
- Pinch bolt (front fork)
Pinch bolt (lower bracket):
20 Nm (2.0 m.kg, 14 ft.lb)
Pinch bolt (handlebar crown):
23 Nm (2.3 m.kg, 17 ftlb)
10. Install:
- Brake caliper
-Holder (brake hose and meter cable)
-Cable band (meter cable and brake hose)
Refer to the "FRONT FORK-INSTALLATION" section.
Bolt (brake caliper):
35 Nm (3.5 m.kg, 25 ftlb)
Bolt (holder):
7 Nm (0.7 m.kg, 5.1 ftlb)
11. Install:
CD
- Front fender
- Holder ~ (brake hose and meter cable)
Bolt (front fender):
8 Nm (0.8 m.kg, 5.8 ftlb)
Bolt (holder):
7 Nm (0.7 m.kg, 5.1 ftlb)
6-57
ICHASI cff;::T01
12. Install:
- Front wheel
Refer to the "FRONT WHEEL-INSTALLATION" section.
,
~~
Axle nut:
85 Nm (8.5 m.kg, 61 ftlb)
13. Install:
-Handlebar
Refer to the "HANDLEBAR-INSTALLATION" section.
Bolt (handlebar):
15 Nm (1.5 m.kg, 11 ftlb)
Bolt (master cylinder bracket):
7 Nm (0.7 m.kg, 5.1 ftlb)
14. Install:
-Cowling (headlight)
Refer to the "HEADLIGHT BULB REPLACEMENT" section in the CHAPTER 3.
Bolt (cowling):
7 Nm (0.7 m.kg, 5.1 ftlb)
6-58
ICHASI~
CD
6-59
CD
Chain case
Chain guide
Q) Swingarm
@ Rubber cover
@ Rubber cap
Pivot shaft
(J) Thrust cover (swingarm)
Shim
Bush
Oil seal
ell
@
@
@
@
@
@
@
@l
Collar
Chain protector
Thrust cover (relay arm)
Collar
Rubber boot
Thrust cover (relay arm)
Relay arm
Collar
Oil seal
Collar
ICHASI ~ I
@ Oil seal
@ Connecting arm
@ Collar
4 Nm
(0.4 mkg, 2.9 ftlb)
7 Nm
10.7 mkg, 5.1 ftlb)
80 Nm
(8.0 mkg, 58 ftlb)
6-60
ICHASI ~ I
HANDLING NOTES
A WARNING
This shock absorber contains highly pressurized nitrogen gas. Read and understand the
following information before handling the
shock absorber. The manufacturer cannot be
held responsible for property damage or personal injury that may result from improper
handling.
-Do not tamper with or attempt to open the
cylinder assembly.
-Do not subject shock absorber to an open
flame or other high heat source. This may
cause the unit to explode due to excessive
gas pressure.
-Do not deform or damage the cylinder in
any way. Cylinder damage will result in
poor damping performance.
-Take care not to scratch the contact surface of the piston rod with the cylinder: or
oil could leak out.
-When scrapping the shock absorber, refer
to the "NOTES ON DISPOSAL" section.
NOTES ON DISPOSAL
*****************************************
A WARNING
Wear eye protection to prevent eye damage
from escaping gas and/or metal chips.
*****************************************
6-61
ICHASI~01
REMOVAL
Rear shock absorber
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
5. Remove:
-Nut CD
-Washer ~
-Bolt @
@ Rubber boot
6. Remove:
-Nut CD
-Washer ~
-Bolt @
- Rear shock absorber @
6-62
ICHASI ~ I
Swingarm
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Place the motorcycle on a level place.
3. Remove:
- Rear shock absorber
Refer to the "REAR SHOCK ABSORBER"
section.
4. Remove:
-Chain case G)
- Chain guide ~
NOTE: _________________________
When removing the chain case, lift up and remove
the chain case from the swingarm L-shaped part
on the back.
5. Remove:
-Nut G) (connecting arm)
-Washer ~
-Bolt
6. Check:
- Swingarm free play
*****************************************
Inspection steps:
Check the tightening torque of the pivot shaft
(swingarm) securing nut G).
Nut (pivot shaft):
80 Nm (8.0 m.kg, 58 ft.lb)
6-63
ICHASI~01
7. Remove :
-Nut
(pivot shaft)
-Washer
- Pivot shaft ~
-Swingarm
CD
8. Remove:
-Rubber boot
-Thrust cover ~ (relay arm)
-Collar
(relay arm-upper)
- Rubber cover
-Thrust cover
(swingarm)
-Shim
-Chain protector Q)
- Collar @ (swingarm)
-Collar (connecting arm)
-Nut
(connecting arm-relay arm)
- Connecting arm Qj)
-Collar (relay arm-lower)
- Rubber cap @
-Nut @ (relay arm-swingarm)
-Relay arm
-Thrust cover
(relay arm)
-Collar @ (relay arm)
CD
6-64
ICHASI #Yel
CD
Oilleaks/Damage~Replace
absorber.
A WARNING
Do not disassemble the shock absorber. because of the highly pressurized nitrogen gas
in it.
2. Inspect:
-Swingarm
Bends/ Cracks/ Damage~ Replace.
CD
-Collars ~
-Shims
Wear / Damage~ Replace.
3. Inspect:
- Relay arm
-Connecting arm ~
Bends/ Cracks/ Damage~ Replace.
CD
-Collars
Wear / Damage~ Replace.
4. Inspect:
-Oil seal
Wear / Damage~ Replace.
-Washer
- Thrust cover
-Collar
Wear / Damage~ Replace.
-Bush
Scratches/ Damage~ Replace.
5. Inspect:
-Chain guide
-Chain protector ~
- Cracks/ Damage ~ Replace.
CD
6-65
ICHASI ~ I
YB276005
2. Measure:
-Collar (swingarm) length @ and
Out of specification--> Replace.
I.
Specified length:
b: 68.75-69.05 mm
(2.707-2.719 in)
c: 63.75-64.05 mm
(2.510-2.522 in)
!ill
3. Measure:
- Pivot width
6-66
ICHASlbe\
Shim thickness @:
0.3 mm (0.012 in)
4. Calculate:
-Swingarm side clearance
Out of specification --> Adjust side cleara nce
using shim.
By using formula given below.
Side clearance:
=(@+@+@)-@
Side clearance: A + B
0.4-0.7 mm (0.016-0.028 in)
~A
::':
::::
::~
*****************************************
Example:
.If the engine mounting boss width
length @, are below.
collar
1?1
6-67
Shim thickness:
0.3 mm (0.012 in)
ICHASI r!;:r01
YB276006
INSTALLATION
Rear shock absorber
Reverse the "REMOVAL" procedure.
Note the following points.
1. Lubricate:
- Bush (inner surface)
2. Install:
-Rear shock absorber
CD (upper side)
3. Tighten:
-Nut
Cll
4. Install:
-Rear shock absorber
CD (lower side)
5. Tighten:
-Nut
Cll
Nut
(lower side):
32 Nm (3.2 m.kg, 23 ft.lb)
6-68
\CHASi r#Y0\
Swingarm
Reverse the "REMOVAL" procedure.
Note the following points.
1. Lubricate:
-Oil seal
-Bushing
-Thrust cover (inside)
-Collar
- Pivot shaft
-Bolt (relay arm-swingarm)
- Bolt (connecting arm - relay arm)
-Bolt (connecting arm-frame)
2. Tighten:
-Nut
(relay arm-swingarm)
-Nut ~ (relay arm-connecting arm)
CD
3. Tighten:
-Nut
(pivot shaft)
CD
CD
Nut
(pivot shaft):
80 Nm (8.0 m.kg, 58 ftlb)
6-69
ICHASI~01
4. Tighten:
-Nut
(connecting arm-frame)
CD
5. Tighten:
- Bolt
(chain case)
-Bolt ~ (chain guide)
CD
6. Install:
- Rear shock absorber
Refer to the "REAR SHOCK ABSORBERINSTALLATION" section.
7. Install:
-Rear wheel
Refer to the "REAR WHEEL-INSTALLATION" section.
8. Adjust:
- Drive chain slack
Drive chain slack:
35-45 mm (1.38-1.77 in)
9. Tighten:
-Axle nut
, ..
~~
Axle nut:
85 Nm (8.5 m.kg. 61 ftlb)
6-70
ICHASI ~ I
10. Install:
-Cotter pin
NOTE: _________________________
CD
A WARNING
Always use a new cotter pin .
349 000
11. Install:
-Fuel tank
-Air scoops
-Seat
-Side covers
6-71
ICHASI ~ I
Driven sprocket
~ Lock washer
@ Chain joint
@ Drive chain
@ Sprocket holder
Drive sprocket
DRIVE CHAIN
B TYPE:
428V1
C NO. OF LINKS:
120
D
1E I USE
6-72
NEW ONE 1
ICHASj r#:Y0j
Y8277000
NOTE: __________________________
Y8277001
REMOVAL
1. Elevate the rear wheel by placing a suitable
stand under the frame and engine.
A WARNING
Securely support the motorcycle so there is
no danger of it falling over.
2. Remove:
CD
Shift arm
Footrest ~ (left)
Crankcase cover 2
3. Loosen:
Drive chain
Refer to the "DRIVE CHAIN SLACK ADJUSTMENT" section in the CHAPTER 3.
4. Remove:
Bolt
(drive sprocket)
.Sprocket holder ~
Drive sprocket
CD
NOTE: __________________________
Loosen the bolt (drive sprocket) while applying
the rear brake.
6-73
ICHASI ~ I
CD
6. Remove:
- Chain joint
Use the drive chain cutter tool
CD.
7. Remove:
- Link plate
-O-ring <Z>
-Joint
- Drive chain
CD
@)
8. Remove:
-Rear wheel
Refer to the "REAR WHEEL-REMOVAL"
section.
YB277002
INSPECTION
1. Measure:
-10-link length (drive chain)
Use the slide caliper tool.
Out of specification-4 Replace drive chain.
10-link length limit:
119.7 mm (4.71 in)
6-74
ICHASI~
NOTE: _________________________
CD~@Q)
IIOgQOftf~
CD
2. Clean:
- Drive chain
Place it in kerosene, and brush off as much
dirt as possible. Then remove the chain from
the kerosene and dry the chain.
000
1111111
1.;: . . - - - - - - - -
3. Inspect:
-O-ring
(drive chain)
Damage-> Replace drive chain.
-Rollers ~
- Link plates @
Damage/Wear-> Replace drive chain.
CD
1111111:;. ________
- Replace the whole drive chain when one 0ring falls off.
-Replace the drive chain, the drive sprocket and the driven sprocket as a set.
6-75
ICHASI~01
4. Inspect:
- Drive chain stiffness
Stiff-> Clean and lubricate or replace.
343007
5. Inspect:
- Drive sprocket
- Driven sprocket
More than 1/4 teeth
wear-> Replace
sprocket.
Bent teeth -> Replace sprocket.
CD
~ Correct
Roller
Sprocket
@
@
343-{)14
*****************************************
Replacement steps:
Straighten the lock washer
tabs and remove the fitting nuts ~. Then remove the
driven sprocket @.
Install a new driven sprocket and lock washers.
NOTE: __________________________
CD
A WARNING
Always use new lock washers.
"
~~
INSTALLATION
Reverse the "REMOVAL" procedure.
Note the following points.
1. Lubricate:
- Drive chain
-Chain joint (new)
Drive chain lubricant:
SAE 30 - 50W motor oil or
chain lubricants suitable for
"O-ring" chains.
6-76
ICHASI~
2. Install:
-Rear wheel
Refer to the "REAR WHEEL-INSTALLATION" section.
3. Install:
- Drive chain G)
- Drive sprocket ~
-Sprocket holder
- Bolt (drive sprocket)
4. Install:
- Chain joint G)
-O-ring ~
- Link plate
Use the drive chain cutter tool
@.
PIN. YM-33858
5. Install:
- Chain joint clip
jl lililll;j
G)
---------------------
IAl
6-77
Turning direction
ICHASI r#Y01
6. Adjust:
- Drive chain slack
Refer to the "DRIVE CHAIN SLACK ADJUSTMENT" section in the CHAPTER 3.
Drive chain slack:
35-45 mm (1.38-1.n in)
Too small chain slack will overload the engine and other vital parts; keep the slack within the specified limits.
7. Tighten:
-Axle nut
- Bolt (drive sprocket)
,
~~
Axle nut:
85 Nm (8.5 m.kg, 61 ftlb)
8. Install:
-Cotter pin
NOTE: _________________________
Bend the ends of the cotter pin as illustration.
A WARNING
Always use a new cotter pin.
349 -000
9. Install:
- Bolt (drive sprocket)
-Crankcase cover 2 (drive sprocket)
- Footrest (left)
-Shift arm
Refer to the "ENGINE OVERHAULENGINE ASSEMBLY AND ADJUSTMENT"
section in the CHAPTER 4.
Bolt (drive sprocket):
10 Nm (1.0 m.kg, 7.2 ftlb)
Bolt (crankcase cover 2):
7 Nm (0.7 m.kg, 5.1 ftlb)
Bolt (shift arm):
10 Nm (1.0 m.kg, 7.2 ftlb)
Bolt (footrest):
32 Nm (3.2 m.kg, 23 ftlb)
6-78
IELEC I 53 I
ELECTRICAL
XT225D/DC CIRCUIT DIAGRAM
W
W
@~
B/ W
OFF
Q)-
R/ W
I@
TB
~I@
l /W
B R Br
ON
B/ W
-:;1;:-
lIY
IllW
@fl
r
@
-:;:-
-4:B
~
Br
@t
p
B/ Y
ll@
@\
J.-
@b\
-*-
7-1
*-
...L
CD
@)
@
@
@
@
@
@
@
@
@
@
C.D.I. magneto
~ Starter motor
Q) Rectifier/Regulator
@ Starter relay
"START" switch
"ENGINE STOP" switch
(J) Battery
Fuse (main)
Main switch
"LIGHTS" (dimmer) switch
(jJ) Head light
@ "HIGH BEAM" indicator light
@ Neutral relay
@ Sidestand switch
@ C.D.I. unit
@ Ignition coil
@ Spark plug
"TURN" switch
@
@
@
@
I lsi
ELEC
Flasher relay
Horn
"TURN" indicator light
Rear flasher light (L)
Front flasher light (L)
Front flasher light (R)
Rear flasher light (R)
"HORN" switch
"NEUTRAL" indicator light
Neutral switch
Clutch switch
Starting circuit cut-off relay
Rear brake switch
Front brake switch
Tail / Brake light
Front position light
Meter light
NOTE: _____________________________________________________________
-"START" switch is closed while the button (switch) is pushed.
-"HORN" switch is closed while the button (switch) is pused.
-Clutch switch is closed while the clutch lever is pulled.
-Sidestand switch is closed while the sidestand is upped.
-Neutral switch is closed while the transmission is in neutral.
-Brake switch is closed while the brake is applied.
COLOR CODE
B
Black
Orange
B/ W
Black / White
Br
Brown
Pink
BIY
Black / Yellow
Ch
Chocolate
Red
Br / W
Brown / White
Dg
Dark green
Sb
Sky blue
L/W
Blue / White
Green
White
L/Y
Blue / Yellow
Blue
Yellow
R/ W
Red / White
7-2
ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS
IELEC IE3 I
BATTERY:
CAPACITY: 12V 6AH
SPECIFIC GRAVITY: 1.320
CD
Wireharness
<l) C.D.I. unit
Q) Neutral relay
@ Fuse (main)
@ Battery
@ Sidestand switch
(j) Neutral switch
Main switch
Ignition coil
@ Spark plug cap
IGNITION COil:
PRIMARY COil RESISTANCE:
0.56 - 0.840 at 20C (68F)
SECONDARY COil RESISTANCE:
5.68 - 8.52kO at 20C (68F)
7-3
ELECTRICAL COMPONENTS
CD
q)
@
@
@
@
I ELEC I E3 I
Rectifier / Regulator
Starter relay
Rear brake switch
Horn
Starting circuit cut-off relay
Flasher relay
7-4
CHECKING OF SWITCHES
IELEC I53 I
YB2S1 000
CHECKING OF SWITCHES
NOTE: _________________________
This section is written based on a general model.
Check the switches for the continuity between
the terminal to determine correct connection.
Read the following for switch inspection.
YB2S1001
B/W
ON
OFF
LOCK
p
0- ~
0- ~
0- f-o
Br
0- f----o
0- j--o
In this chart:
"R" and 8r" and "L/W and L/R" are continuous with the "ON" switch position.
-0
UW UR
7-5
_________
C_H_E_C_K_IN_G_O_F_S_W_IT_C_H_E_S_I
ELEC
I53 I
YB28 1002
7-6
~~~~~~~~~C_H_E_C_K_IN_G~O_F_S_W_IT_C_H_E_S~IELECI ~ I
3. Use the connection chart to check the color
combination for continuity (a closed circuit).
In this example, the continuity is as follows.
10 f----O
10 f----O
10 k) 0
ro
0- f-{)
"R and Br" and "L/W and L/ R" are continuous with the "ON" switch position.
-0
'il Br
rfR
L/R
L/W
lX
4. Check the switch component for the continuity between "R and Br".
"0"
Checking steps:
.Turn the switch key to the "ON", "OFF",
"LOCK" and "P" several times.
Set the pocket tester selector to the "0 x 1".
Connect the tester ( + ) lead to the "R" lead terminal in the coupler and the (-) lead to the
"Br" lead terminal.
NOTE: _________________________
Use thin probes for checking the continuity.
Otherwise, the probes may contact other terminals inside the coupler.
CD,
7-7
CHECKING OF SWITCHES
"OFF" or "LOCK" or "P" .
NOTE: __________________________
Check the switch for continuity several times.
*****************************************
5. Next go on to checking of the continuity between "8" and "8/W", "UW and UR", and
"R and U R" at the respective switch positions, as in the same manner mentioned
above.
6. If there is something wrong with anyone of
the combinations, replace the switch component.
7-8
CHECKING OF BULBS
IELEC lSi
Y8282000
KINDS OF BULBS
The bulbs used in the motorcycle are classified
as shown left by the shape of the bulb socket.
Y8282002
7-9
~~~~~~~~~~C_H_E_C_K_IN_G~O_F_B_U_L_B_S~IELECI~ I
Be sure to hold the socket firmly when
removing the bulb. Never pull the lead.
Otherwise, the lead may be pulled off the terminal in the coupler.
A WARNING
Keep flammable products or your hands
away from the headlight bulb while it is on.
It will be hot. Do not touch the bulb until it
cools down.
Checking steps:
Set the pocket tester selector to the "n x 1" .
Connect the tester lead to the respective bulb
terminals. Take for example a 3-terminal bulb
as shown left. First check the continuity between the
and (2) terminal by connecting
the tester ( + ) lead to the
terminal and the
tester ( - ) lead to the (2) terminal. Then check
the continiuty between the
and
terminals by connecting the tester ( +) lead still to
the
terminal and the tester ( - ) lead to the
terminal. If the tester shown "CXJ" in either
case, replace the bulb.
CD
CD
CD
CD
*****************************************
7-10
IGNITION SYSTEM
IGNITION SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows ignition system.
7-11
IELEC I53 I
IGNITION SYSTEM
NOTE: _________________________
For the color codes, see page 7-2.
CD
(f)
@
@
@
@
@
C.O.I. magneto
"ENGINE STOP" switch
Battery
Fuse (main)
Main switch
Neutral relay
Sidestand switch
C.O.I. unit
Ignition coil
Spark plug
Neutral switch
7-12
I IS i
ELEC
____________
,G_N_,T_,_O_N_S_y_S_T_E_M_1
IGNITION CONTROL CIRCUIT OPERATION
Transmission
(Neutral switch)
CD
Battery
~ Fuse (main)
Q) Main switch
@
(J)
C.D.1. magneto
C.D.1. unit assembly
C.D.1. unit
Ignition control unit
(jJ)
>
ELEe
lsi
Sidestand
Spark
Sidestand switch) plug
fA!
Neutral
(close)
Up
(close)
Spark
fA!
Neutral
(close)
Down
(open)
Spark
fA!
IN gear
(open)
Up
(close)
Spark
lm
IN gear
(open)
Down
(open)
No
spark
Thyristor
Neutral relay
Neutral switch
Sidestand switch
Ignition coil
Spark plug
==l
Bypass current
==::CD
~
Q)
,--------------------------1
" @~:
,----1
i
I
I
'------' I
i_____ J
II
/ /
ii
I
Bypass current flows into the thyristor which is L
thus turned on, there by grounding the current
of the sourse coil. In this way, no sparks will be
produced.
//
/
--------./
7-13
/)
rUl:-]
IGNITION SYSTEM
TROUBLESHOOTING
IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE
(NO SPARK OR INTERMITTENT SPARK)
Procedure
Check:
1. Fuse (main)
2. Battery
3. Spark plug
4. Ignition spark gap
5. Spark plug cap resistance
6. Ignition coil resistance
7. Main switch
8.
9.
10.
11.
12.
13.
14.
1. Fuse (main)
NOCONTINUITY
. . v .,
....
'"
CONTINUITY
2. Battery
INCORRECT
Voltage:
12.8V or higher at 20C (68F)
....u.,
CORRECT
7-14
IGNITION SYSTEM
IELEC lSi
3. Spark plug
- Check the spark plug condition.
-Check the spark plug type.
-Check the spark plug gap.
Refer to the "SPARK PLUG INSPECTION"
section in the CHAPTER 3.
INCORRECT
CD
MEETS SPECIFICATION
t-----------.
OUT OF SPECIFICATION
OR NO SPARK
*
7-15
IGNITION SYSTEM
IELEC Ia I
OUT OF SPECIFICATION
-Check the spark plug cap for specified
resistance.
~
~
MEETS
SPECIFICATION
6. Ignition coil resistance
- Disconnect the ignition coil leads from the ignition coil.
-Connect the pocket tester mx l) to the ignition coil.
G:J
-@+
~------------~~
7-16
IGNITION SYSTEM
Connect the pocket tester
nition coil.
IELEC I53 I
CD
INCORRECT
.Check the secondary coil for specificated
resistance.
Secondary coil resistance:
5.68 - 8.52kQ at 20 0 (68F)
(Spark plug lead - Body earth
BOTH MEET
SPECIFICATIONS
7. Main switch
Disconnect the main switch coupler from the
wire harness.
Check the switch component for the continuity between "Red G) and Brown CZ)", "Black
and Black / White @".
Refer to the "CHECKING OF SWITCHES"
section.
INCORRECT
7-17
~~~~~~~~~~~_IG_N_IT_I_O_N_S_Y_S_T_E_M~IELECI ~ I
8. "ENGINE STOP" switch
Disconnect the handlebar switch (right) coupler from the wireharness.
Check the switch component for the continuity between "Red/White
and Red/White
(2)". Refer to the "CHECKING OF
SWITCHES" section.
CD
INCORRECT
9. Neutral switch
Disconnect the neutral switch lead from the
wireharness .
Check the switch component for the continuity between "Sky blue
and ground". Refer
to the "CHECKING OF SWITCHES" section.
CD
INCORRECT
I
CORRECT
7-18
IGNITION SYSTEM
IELEC I53 I
*
~
10. Sidestand switch
Disconnect the sidestand switch coupler from
the wireharness.
Check the switch component for the continuity between "Black
and Black C,l)".
Refer to the "CHECKING OF SWITCHES"
section.
CD
INCORRECT
M
flxl
-@+
NO CONTINUITY
7-19
IGNITION SYSTEM
IELEC Is I
*
~
12. Charge coil resistance
- Disconnect the charge coil coupler from the
wireharness.
-Connect the pocket tester (step 1 .... n x 100),
(Step 2 .... n x 10) to the charge coil terminal.
Step 1:
Tester (+) lead--Brown lead G)
Tester ( .... ) If'?~ .....r~~p~n lead @
Step 2:
Tester (+) lead--Yellow lead @
Tester ( .... ) lead--Frame ground
OUT OF SPECIFICATION
MEET SPECIFICATION
7-20
IGNITION SYSTEM
IELEC Ie I
OUT OF SPECIFICATION
MEET SPECIFICATION
POOR CONNECTION
14. Wiring connection
Check the entire ignition system for connections.
Refer to the "WIRING DIAGRAM' section.
CORRECT
7-21
Correct
IGNITION SYSTEM
7-22
I ELEC
lSi
-=1-
7-23
ELEC
lei
ell
Starter motor
@ Starter relay
@ "START" switch
(J) Battery
@ Fuse (main)
Main switch
@ Sidestand switch
@ Neutral switch
@ Clutch switch
7-24
IELEC Is I
IELEC lSi
YB28400 1
= CD
---,
@
I
I
I
I
I
I
I
I
L ____ ~
The starting circuit cut-off relay prevents the starter from operating when neither of these conditions has been met . In this instance, the starting
circuit cut-off relay is open so current cannot
reach the starter motor .
-1
@ M
~
o
-=
CD
Battery
Main switch
Clutch switch
7-25
IELEC lSi
TROUBLESHOOTING
STARTER MOTOR DOES NOT OPERATE.
Procedure
Check:
1. Fuse (main)
2. Battery
3. Starter motor
4. Starter relay
5. Starting circuit cut-off relay
6. Main switch
7. "ENGINE STOP" switch
8.
9.
10.
11.
12.
Neutral switch
Clutch switch
Sidestand switch
"START" switch
Wiring connection
(Entire electric starting system)
NOTE: _____________________________________________________________
-Remove the following parts before troubleshooting.
1} Side covers
2} Seat
3} Cowling
-Use the following special tool in this troubleshooting.
Pocket tester:
PIN YM-03112. 90890-03112
NOCONTINUITY
1. Fuse (main)
- Remove the fuse.
- Connect the pocket tester
xl} to the fuse.
-Check the fuse for continuity.
CONTINUITY
V
2. Battery
INCORRECT
Voltage:
12.8V or higher at 20C (68F)
jJ..
CORRECT
7-26
_ _ _ _ _ _ _E_L_E_C_T_R_IC_A_L_S_T_A_R_T_IN_G_S_Y_S_T_E_M_I
ELEC
Is I
*A WARNING
3. Starter motor
CD
* as shown.
MOVES
4. Starter relay
- Disconnect the starter relay coupler from the
wireharness.
- Connect the battery to the starter relay leads
as shown using the jumper leads
CD.
MOVES
.;!;!:II:III(II'~;!;!.
-Take care not to reverse the battery connections because the diode will be
damaged.
-Take care to avoid shorting the positive and
negative terminals at the time of connecting the battery and relay.
________
as shown.
7-27
IELEC I 53 I
NOCONTINUITY
CONTINUITY
6. Main switch
Disconnect the main switch coupler from the
wireharness .
Check the switch component for the continuity between "Red
and Brown (2)".
Refer to the "CHECKING OF SWITCHES"
section.
CD
INCORRECT
I
7. "ENGINE STOP" switch
Disconnect the handlebar switch (right) coupler from the wireharness.
Check the switch component for the continuity between "Red / White
and Red / White
(1) ". Refer to the "CHECKING OF
SWITCHES" section.
CD
7-28
IELEC I 53 I
INCORRECT
INCORRECT
OFF
(Release)
INCORRECT
7-29
IELEC I 53 I
.u.
10. Sidestand switch
Disconnect the sidestand switch coupler from
the wireharness.
Check the switch component for the continuity between "Black
and Black (g)".
Refer to the "CHECKING OF SWITCHES"
section.
CD
INCORRECT
CD
INCORRECT
CORRECT
POOR CONNECTION
12. Wiring connection
Check the entire ignition system for connections.
Refer to the "WIRING DIAGRAM" section.
I
7-30
Correct.
IELEC
lSi
STARTER MOTOR
CD
<V
Q)
@
(j)
(jJ)
r-- -----------------.....
I
"
I
I
I
I
MICA UNDERCUT:
"
"
"
"
,
"
I
I
"
'
I
I
I
',,~
,
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
l.
,,
,,
,,
,,
,,
,,
"'-
"'-
"'-
"'-
----------------------7-31
IELEC I53 I
Y8284002
Removal
1. Remove:
Engine guard
Refer to the "ENGINE OIL REPLACEMENT"
section in the CHAPTER 3.
2. Disconnect:
Battery negative lead G)
Refer to the "BATTERY INSPECTION" section in the CHAPTER 3.
3. Remove:
Starter motor lead
Starter motor (2)
G)
Disassembly
1. Put identifying marks G) on the brackets for
reassembly as shown.
2. Remove:
Front bracket
7-32
G)
IELEC 181
3. Remove:
-Washer
-Shim ~
CD
4. Remove:
- Rear bracket
CD
5. Remove :
-Armature assembly
-Yoke ~
6. Remove:
- Brush springs
CD
CD
~~~~~~_E_L_EC_T_R_I_C_A_L_S_T_A_R_T_lN_G_S_Y_S_T_E_M~IELECI~
3. Measure:
-Mica undercut
Out of specification ---+ Scrape the mica to
proper value use a hacksaw blade can be
ground to fit.
Mica undercut:
1.5 mm (0.06 in)
NOTE: _________________________
The mica insulation of the commutator must be
undercut to ensure proper operation of commutator .
1 MQ or more
4. Inspect:
OQ
Inspecting steps:
Connect the pocket tester for continuity check
and insulation check ~.
Measure the armature resistances.
CD
CD:
5. Measure:
- Brush length
Out of specification ---+ Replace as a set .
Brush length limit:
3.5 mm (0.14 in)
NOTE: ______________________
I ELEC I s I
6. Measure:
- Brush spring force
Fatigue/ Out of specification -> Replace as a
set.
7. Inspect:
-Bearing
-Oil seal
-Bush
Damage-> Replace the bracket.
-O-rings
Wear / Damage-> Replace.
Assembly
Reserve the "Removal" procedure.
Note the following points.
1. Install:
- Brush springs
-Brush ~
-Brush @
CD
NOTE: _________________________
-When installing the brush ~, pass the brush
lead outside of the projection
on the brush
spring holder.
-When installing the brush @, install the brush
lead terminal
to touch lightly to the projection
on the side of brush spring holder.
2. Install:
-Armature
CD
NOTE: ________________________
__
When installing the armature, press the brush
with thin screwdriver, etc. to avoid damage to the
brush and install.
7-35
IELEC
lSi
G)
4. Install:
-Yoke
G)
NOTE: __________________________
Align the match mark on the yoke with the match
mark on the rear bracket.
5. Install:
-Washer G)
-Shim ~
- Front bracket
NOTE: ________________________
__
- Align the projection of the washer G) with the
slot of the front bracket
and install.
- Align the match marks
on the yoke with the
match marks on the brackets.
1)iJ
Bolt:
5 Nm (0.5 m okg, 3.6 ftolb)
IE,
Installation
1. Apply:
- Starter motor
NOTE:
__________________________
Apply a lightly grease to the a-ring
7-36
G) .
Install:
-Starter motor
-Starter motor lead
IELEC lSi
CD
(2)
3. Connect:
- Battery negative lead
Refer to the "BATTERY INSPECTION" section in the CHAPTER 3.
4. Install:
- Engine guard
Refer to the "ENGINE OIL REPLACEMENT"
section in the CHAPTER 3.
Bolt (engine guard):
7 Nm (0.7 m.kg, 5.1 ftlb)
7-37
7-38
I lei
ELEC
CHARGING SYSTEM
CHARGING SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows charging system.
7-39
ELEC
I 53 I
CHARGING SYSTEM
NOTE: _________________________
For the color codes, see page 7-2.
CD
C.D.I. magneto
@ Rectifier / Regulator
(j) Battery
Fuse (main)
7-40
I ELEC
lSi
CHARGING SYSTEM
1 181
ELEC
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED.
Procedure
Check:
1. Fuse (main)
2. Battery
3. Charging voltage
4. Stator coil resistance
5. Wiring connection
(Entire charging system)
NOTE: _____________________________________________________________
-Remove the following parts before troubleshooting.
1) Side cover (right)
2) Seat
-Use the following special tool(s) in this troubleshooting.
Inductive tachometer:
PIN Y U -OB036-A, 90B90-03113
Pocket tester:
PIN YU-03112, 90B90-03112
1. Fuse (main)
NOCONTINUITY
""Ij
CONTINUITY
'vii""
2. Battery
INCORRECT
Voltage:
12.BV or higher at 20C (6BOF)
CORRECT
7-41
IELEC Is I
CHARGING SYSTEM
3. Charging voltage
-Connect the inductive tachometer to the
spark plug lead.
-Connect the pocket tester (DC20V) to the
battery.
Tester (+)
Tester ( - )
lead~Battery
lead ~
( + ) terminal
Battery ( - ) terminal
-_____
~- v:-~
~~~-~ I
\ ::f ~
: ~ ~. ~
e r--"-'
' c---. ~ 0
\ ,~f
" .~ ~OC20V
~
\\ \
Y II
'-
-..
iiJ j l'i'J $L
,
'"-T--/
:.1I
MEETS SPECIFICATION
Charging voltage:
14.0V at 5,000 r/min
NOTE:
{,>'
...
,.
OUT OF
SPECIFICATION
G)
G)
7-42
CHARGING SYSTEM
I [sl
ELEC
r---------~,-----------~
OUT OF SPECIFICATION
BOTH MEET
SPECIFICATIONS
POOR CONNECTION
5. Wiring connection
Check the entire ignition system for connections.
Refer to the "WIRING DIAGRAM" section.
I Correct.
OK
7-43
CHARGING SYSTEM
7-44
I ELEC
lSi
LIGHTING SYSTEM
I lei
ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows lighting system.
"*-
7-45
LIGHTING SYSTEM
NOTE: __________________________
For color codes, see page 7-2.
(J) Battery
@
(jJ)
@
@
Fuse (main)
Main switch
"LIGHTS" (dimmer) switch
Headlight
"HIGH BEAM" indicator light
Tail / Brake light
Front position light
Meter light
7-46
IELEC I53 I
LIGHTING SYSTEM
IELEC I53 I
'TROUBLESHOOTING
HEADLIGHT, "HIGH BEAM" INDICATOR LIGHT, TAILLIGHT AND/OR METER LIGHT DO
NOT COME ON
Procedure
Check:
1. Bulb
2. Fuse (main)
3. Battery
4. Main switch
NOTE: _____________________________________________________________
-Remove the following parts before troubleshooting.
1) Side covers
2) Seat
3) Cowling
-Use the following special tool(s) in this troubleshooting.
Pocket tester:
PIN YU-03112, 90890-03112
NOCONTINUITY
"4
V'
CONTINUITY
2. Fuse (main)
NOCONTINUITY
CONTINUITY
"4 .....
"4
:r
7-47
_ _ _ _ _ _ _ _ _ _ _L_IG_H_T_I_N_G_S_Y_S_T_E_M_I
3. Battery
ElEC
I 53 I
INCORRECT
Voltage:
INCORRECT
7-48
LIGHTING SYSTEM
I ELEC I s I
INCORRECT
POOR CONNECTION
6. Wiring connection
Check the entire lighting system for connections.
Refer to the "WIRING DIAGRAM" section.
ICorrect.
CORRECT
7-49
LIGHTING SYSTEM
7-50
I ELEC
lSi
SIGNAL SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM
Below circuit diagram shows signal system.
7-51
I IS I
ELEC
SIGNAL SYSTEM
IELEC I81
NOTE: __________________________
For the color codes, see page 7-2.
@
@
@
@
@
@
@
@
(J) Battery
@ Fuse (main)
Main switch
"TURN" switch
@ Flasher relay
@l Horn
@ "TURN" indicator light
@ Rear flasher light (L)
@ Front flasher light (L)
7-52
1 181
ELEC
SIGNAL SYSTEM
TROUBLESHOOTING
-FLASHER LIGHT. BRAKE LIGHT AND/OR INDICATOR LIGHT DO NOT COME ON.
-HORN DOES NOT SOUND.
Procedure
Check:
1. Fuse (main)
2. Battery
3. Main switch
4. Wiring connection
(Entire signal system)
NOTE: ___________________________________________________________
-Remove the following parts before troubleshooting.
1) Seat
2) Side covers
3) Air scoops
4) Fuel tank
5) Cowling
-Use the following special tool in this troubleshooting.
Pocket tester:
PIN YU-03112. 90890-03112
1. Fuse (main)
NOCONTINUITY
- Remove the fuses.
- Connect the pocket tester x 1) to the fuses.
- Check the fuses for continuity.
Refer to the "FUSE INSPECTION" in the
CHAPTER 3.
..ll-
....
CORRECT
2. Battery
INCORRECT
Voltage:
12.8V or higher at 20 D C (68 D F)
~
*
7-53
SIGNAL SYSTEM
IELEC I 53 I
3. Main switch
Disconnect the main switch coupler from the
wireharness.
Check the switch component for the continuity between" Red G) and Brown 0". Refer
to the "CHECKING OF SWITCHES" section.
INCORRECT
CORRECT
4. Wiring connection
POOR CONNECTION
7-54
SIGNAL SYSTEM
I IS I
ELEC
CD
INCORRECT
CD
OUT OF SPECIFICATION
MEETS
SPECIFICATION (12V)
7-55
SIGNAL SYSTEM
I Is I
3. Horn
- Disconnect the "Pink" lead from the horn
terminal.
-Connect a jumper lead
to the horn term inQI and ground the jumper lead .
-Turn the main switch to "ON".
CD
TBr
HORN IS SOUNDED
Horn is good.
HORN IS NOT
SOUNDED
4. Voltage
- Connect the pocket tester (DC20V) to the
horn at the "Pink" terminal.
CD
OUT OF SPECIFICATION
-Turn the main switch to "ON".
-Check for voltage (12V) on the "Pink" lead
at the horn terminal.
MEETS SPECIFICATION
(12V)
ELEC
SIGNAL SYSTEM
IELEC I 53 I
NOCONTINUITY
1. Bulb and bulb socket
-Check the bulb and bulb socket for continuity.
Refer to the "CHECKING OF BULBS"
section.
CONTINUITY
2. Brake switch
- Disconnect the brake switch leads from the
wireharness.
- Check the switch component for the continuity between " Green / Yellow
and Brown
"Black
and Black @". Refer to the
"CHECKING OF SWITCHES" section.
ClJ",
CD
ON
(Depress)
OFF
IFree)
, ~~
~
G/ Y
I
IAl
INCORRECT
Q
Br
I
SIGNAL SYSTEM
ELEC
lSi
<}-y~
<}-l
<}-B
OUT OF SPECIFICATION
-Turn the main switch to "ON".
-The brake lever is pulled in or brake pedal is
depressed.
Wiring circuit from main switch to bulb sock- Check for voltage (12V) on the "Yellow" lead
et connector is faulty, repair.
at the bulb socket connector.
MEETS
SPECIFICATION (12V)
CONTINUITY
2. "TURN" switch
- Disconnect the handlebar switch (left) coupler from the wireharness.
-Check the switch component for the continuity between "Brown / White
and Chocolate
(2)" and "Brown / White
and Dark green
Q) ". Refer to the "CHECKING OF
SWITCHES" section.
CD
CD
INCORRECT
7-58
I ELEC I s I
SIGNAL SYSTEM
3. Voltage
- Connect the pocket tester (DC20V) to the
flasher relay.
Tester (+) lead ..... Brown lead G)
Tester (-) lead ..... Black lead @
OUT OF SPECIFICATION
MEETS
SPECIFICATION (12V)
4. Voltage
-Connect the pocket tester (DC20V) to the
flasher relay.
Tester (+) lead ..... Brown/White lead
Tester (-) lead ..... Black lead @
G)
OUT OF SPECIFICATION
7-59
replace it.
re ~
SIGNAL SYSTEM
IElEC lSi
*
~
5. Voltage
- Connect the pocket tester (DC20V) to the
bulb socket connector.
At flasher light (left):
Tester (+) lead-->Chocolate lead
Tester (-) lead-->Frame ground
G)
G
8
DC20V
Ch
G
8
DC20V
D9
OUT OF SPECIFICATION
MEETS
SPECIFICATION (12V)
NOCONTINUITY
- Check the bulb and bulb socket for continuity. Refer to the "CHECKING OF BULBS"
section.
CONTINUITY
"",,",
*
7-60
~~~~~~~~~~~~SI_G_N_A_l_S_Y_S_T_E_M_IELECI ~
*
~
2. Neutral switch
- Disconnect the neutral switch lead from the
wireharness.
- Check the switch component for the continuity between "Sky blue G) and Ground". Refer
to the "CHECKING OF SWITCHES" section.
INCORRECT
3. Voltage
- Connect the pocket tester (DC20V) to the
bulb socket connector.
CD
OUT OF SPECIFICATION
Wiring circuit from main switch to bulb socket connector is faulty, repair.
MEETS
SPECIFICATION (12V)
7-61
_ _ _ _ _ _ _ _ _ _ _ _S_I_G_N_A_L_S_y_S_T_E_M_1
ELEC
181
NOCONTINUITY
7-62
TROUBLESHOOTING
NOTE: ___________________________________________________________
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection,
adjustment and replacement of parts.
PROBABLE CAUSE
Fuel tank---------r-l-Empty
-Clogged fuel filter
- Clogged fuel strainer
-Clogged fuel breather hose
- Detenorated fuel or fuel containing water or
foreign material
Fuel cock
hose
- Clogged fuel filter
8-1
---------,-l-
ELECTRICAL SYSTEM
Spark plug
PROBABLE CAUSE
-Improper plug gap
-Worn electrodes
-Wire between terminals broken
-Improper heat range
- Faulty spark plug cap
motor
relay
cut-off relay
clutch
L-
PROBABLE CAUSE
COMPRESSION SYSTEM
Cylinder and cylinder head
starter
starter
circuit
starter
8-2
PROBABLE CAUSE
battery
spark plug
C.D.I. unit
pulser coil
charge coil
ignition coil
PROBABLE CAUSE
carburetor--------'l-_Improper jet needle clip position
- Diaphragm malfunction
-Improperly adjusted fuel level
-Clogged or loose main jet
- Deteriorated fuel containing water or foreign
material
Air cleaner----------Clogged air filter element
8-3
FA_U_L_T_Y_G_E_A_R
__S_H_~
__
IN_G_/_lsTHRTBGLI
_ _________________
CLUTCH
SLIPPING/DRAGGING
_
_ ?
FAULTY GEAR SHIFTING
HARD SHIFTING
Refer to the "CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING" section.
SHIFT PEDAL DOES NOT MOVE
PROBABLE CAUSE
JUMP-OUT GEAR
PROBABLE CAUSE
CLUTCH SLIPPING/DRAGGING
----------.l-
CLUTCH SLIPPING
Clutch
Engine
Oil--------~L
PROBABLE CAUSE
-Loose clutch spring
- Fatigued clutch spring
-Worn friction plate
- Worn clutch plate
-I ncorrectly assembled clutch
-Low oil level
-Improper quality (Low vIscosity)
- Deterioration
8-4
_ _____________________________
OVERHEATING OR OVER-COOLING ISTHRTBGLI
_
_ ?
CLUTCH DRAGGING
PROBABLE CAUSE
OVERHEATING
OVERHEATING
PROBABLE CAUSE
8-5
A_K_A_G_E_lsTHRTBGL
I.
AND FRONT FORK MALFUNCTION
_
_ _ _F_A_U_L_T_Y_B_R_A_K_E_I_FR_O_NT_F_O_R_K_O_I_L_L_E_
FAULTY BRAKE
POOR BRAKING EFFECT
PROBABLE CAUSE
Disc brake--------~-Worn brake pad
-Worn brake disc
- Air in brake fluid
- Leaking brake fluid
- Faulty cylinder kit cup
- Faulty caliper kit seal
- Loose union bolt
- Broken brake hose
-Oily or greasy brake disc
- Oily or greasy brake pad
-Improper brake fluid level
OIL LEAKAGE
MALFUNCTION
PROBABLE CAUSE
deformed or damaged inner tube
- Bent or deformed outer tube
- Damaged fork spring
-Worn or damaged guide bush
- Bent or damaged damper rod
-Improper oil viscosity
-Improper oil level
'--------------~-Bent,
8-6
_ ____________________________
INSTABLE HANDLING ISTHRTBGLI
_
. ?
INSTABLE HANDLING
INSTABLE HANDLING
PROBABLE CAUSE
-----------,-l-
------------,--l-
F r a m e - - - - - - - - - - - r - - -Twisted
- Damaged head pipe
L -Improperly Installed bearing or ball race
Swingarm - - - - - - - - - - - r - L -Worn collar or bush
- Bent or damaged
Rear shock absorber - - - - - T L - - Fatigued spring
-Improperly adjusted spring preload
- Oil and gas leakage
Drive chain-----------Improperly adjusted chain slack
8-7
_ ____________________________
FAULTY SIGNAL AND LIGHTING SYSTEM ISTHRTBGLI
_
. ?
FAULTY SIGNAL AND LrGHTING SYSTEM
PROBABLE CAUSE
HEADLIGHT DARK
1 - . . - - - - - - - - - - - - - , - - l m p r o p e r bulb
-Too many electric accessories
-Hard charging (Broken stator coil and/or faulty
rectifier / regulator)
-Incorrect connection
-Improperly grounded
-Poor contacts main or "LIGHTS" (Dimmer)
switch
- Bulb life expired
PROBABLE CAUSE
L..-------------~-Improper bulb
- Faulty battery
- Fau Ity rectifier / regu lator
-Improperly grounded
-Faulty main and/or "LIGHTS" (Dimmer) switch
- Bulb life expired
PROBABLE CAUSE
'--------------~-Improperly grounded
- Discharged battery
-Faulty "TURN" switch
- Faulty flasher relay
- Broken wireharness
- Loosely connected coupler
-Bulb burnt out
PROBABLE CAUSE
FLASHER KEEPS ON
8-8
_ _____________________________
FAULTY SIGNAL AND LIGHTING SYSTEM"ISTHRTBGLI.
PROBABLE CAUSE
FLASHER WINKS SLOWER
' - - - - - - - - - - - - - - , - - - Faulty flasher relay
-I nsufficient battery capacity
(nearly discharged)
-Improper bulb
-Faulty main and/or "TURN" switch
PROBABLE CAUSE
L -Improper bulb
- Fau Ity flasher relay
HORN IS INOPERATIVE
PROBABLE CAUSE
8-9
MOTORCYCLE IDENTIFICATION
I ~~~ ~I
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number CD is stamped
into the right side of the steering head.
NOTE: _____________________
The vehicle identification number is used to
identify your motorcycle and may be used to
register your motorcycle with the licensing authority in your state.
NOTE: _____________________
-The first three digits of these numbers are for
model identifications; the remaining digits are
the unit production number.
-Designs and specifications are subject to
change without notice.
-1-
GENERAL SPECIFICATIONS
SPEC I
~I
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
XT225H/HC
Shock absorber:
Front
Rear
Coil-Spring/Oil damper
Coil-Gas spring/Oil damper
-2-
MAINTENANCE SPECIFICATIONS
ISPEC JU-J
MAINTENANCE SPECIFICATIONS
ENGINE
Model
XT225H/HC
~
Carburetor:
I.D. Mark
Main jet
Main air jet size
Jet needle
Needle jet
Pilot air jet size
Pilot jet
Pilot outlet
Bypass 1
Pilot screw
Valve seat size
Starter jet
USA
(M.J.)
(M.A.J.)
(J.N.)
(N.J.)
(P.A.J.l)
(P.A.J.2)
(P.J.)
(P.O.)
(B.P.l)
(P.S.)
(V.S.)
(G.S.l)
(G.S.2)
(F.L.)
Float height
(F.H.)
~"D'
~. ~c.
48E 10
#130
1.0
5DL27-1
0-1
#60
1.2
#40
0.85
0.8
Preset
2.0
#60
0.7
California
48E 00
CDN
f-
3RWOl
#122.5
0.9
5GN50-3/5
0-0
#80
1.2
#42.5
f-
f-
f-
f-
f-
2 turns out
f-
f-
f-
#45
f-
f-
ffffff-
-3-
MAINTENANCE SPECIFICATIONS
ISPEC I~ I
TIGHTENING TORQUE
Thread
Part to be tightened
Part name
Tightening torque
Q'ty
size
Cylinder head
Cylinder head and cylinder
Cylinder head
Cylinder head side cover 3
Cylinder head side cover 12
Plate
Spark plug
Cylinder
Balance weight gear
AC generator rotor
Valve clearance
Cam sprocket
Tensioner
Stopper guide 2
Oil pump assembly
Drain plug 1
Element cover
Element cover
Element cover
Carburetor joint 1
Carburetor
Air filter case fitting (front)
Remarks
Nm
mokg ftolb
Cross recessed
hexagon bolt
Flange bolt
M6
0.7
5.1
Oilcheck
MB
22
2.2
17
Apply oil to
the washer
Bolt
Panhead screw
Bolt
Bolt
MB
M6
M6
M6
M12
M6
M14
M10
M6
M10
M6
M6
M6
M35
M6
M6
M6
M6
M5
M6
2
2
5
2
1
2
1
1
2
1
2
2
3
1
1
1
1
2
1
1
20
7
10
B
17.5
10
50
50
13.5
60
10
B
7
43
7
7
10
12
2
10
2.0
0.7
1.0
O.B
1.75
1.0
5.0
5.0
1.35
6.0
1.0
O.B
0.7
4.3
0.7
0.7
1.0
1.2
0.2
1.0
14
5.1
7.2
5.B
12.5
7.2
36
36
10
43
7.2
5.B
5.1
31
5.1
5.1
7.2
B.7
1.4
7.2
M6
10
1.0
7.2
MB
M6
M6
2
2
3
40
10
7
4.0
1.0
0.7
29
7.2
5.1
Bolt
Nut
Bolt
Nut
Bolt
Bolt
Bolt
Flat head screw
Muffler mounting
Exhaust pipe fitting
Exhaust pipe protector
Panhead screw
Panhead screw
Bolt
Button head bolt
Hose clamp
Screw with
washer
Hexagon bolt
with washer
Flange bolt
Bolt
Bind head screw
Muffler protector
Screw
M6
0.7
5.1
Bolt
Panhead screw
Pan head screw
Panhead screw
MB
M6
M6
M6
1
7
2
2
20
7
7
7
2.0
0.7
0.7
0.7
14
5.1
5.1
5.1
Case 1 & 2
Panhead screw
M6
0.7
5.1
-4-
Use 10Ck_~
washer
Use lock-G
washer
Tighten starter
motor together
I Iu-I
SPEC
MAINTENANCE SPECIFICATIONS
Thread
Part to be tightened
Tightening torque
Q'ty
Part name
size
Crankcase cover 1
Crankcase cover 1
Clamp
Crankcase cover 2
Crankcase cover 3
Crankcase cover 3
Crankcase cover 3
Primary drive gear
Clutch spring
Clutch boss
Push lever assembly stopper
Push lever clearance adjusting
Drive sprocket
Shift pedal
Segment
Pulser coil
Neutral switch assembly
Stator coil
Remarks
Nm
mokg ft-lb
Panhead screw
Panhead screw
Panhead screw
Pan head screw
Pan head screw
Panhead screw
Panhead screw
Nut
Screw with
washer
Nut
Screw
Nut
Bolt
Bolt
Screw
M6
M6
M6
M6
M6
M6
M6
M14
M5
6
2
1
2
5
3
2
1
4
7
7
7
7
7
7
7
50
6
0.7
0.7
0.7
0.7
0.7
0.7
0.7
5.0
0.6
5.1
5.1
5.1
5.1
5.1
5.1
5.1
36
4.3
M14
M8
M6
M6
M6
M6
1
1
1
2
1
1
70
12
8
10
10
12
7.0
1.2
0.8
1.0
1.0
1.2
51
8.7
5.8
7.2
7.2
8.7
Panhead screw
M6
Ml0
M5
2
1
3
7
20
4
0.7
2.0
0.4
5.1
14
2.9
-5-
Torques bolt
-(J
-Iel
-(fJ
MAINTENANCE SPECIFICATIONS
ISPEC I
g--I
CHASSIS
Model
Front suspension:
Front fork travel
Front spring free length
<Minimum free length>
Spring rate
Stroke
XT225H/HC
(K1)
(K2)
(K1)
(K2)
Optional spring
Oil capacity
Oil level
Oil grade
Rear suspension:
Shock absorber travel
Spring free length
Fitting length
Spring-rate
Stroke
Optional spring
Enclosed gas pressure
(Kl)
(Kl)
72 mm (2.8 in)
189 mm (7.4 in)
174 mm (6.9 in)
61.5 N/mm (6.15 mm, 344 Ib/in)
Zero-87 mm (Zero-3.4 in)
No
2000 kPa (20 kg/cm 2 , 284 psi)
-6-
SPEC
..
Lubricant type
o4ls-t
~
~L~
~LS'"
..CLs. . .
~~
Collar (swingarm)
~M-t
~M'"
~M'"
~M'"
~M'"
~M-t
-CM-t
-CM-t
~M'"
___
....
....
..
M~
~LS'"
-7-
10--1
CABLE ROUTING
-------------------------------------------------------------
ISPECI g-I
CABLE ROUTING
CD
Clutch cable
@ Master cylinder
Q) Front brake hose
@ Throttle cable
(j)
@
@
@
@
@
@
@
Band
Throttle cable
Band
Clutch cable
Handlebar switch lead (left)
Clutch switch lead
Speedometer lead
Flasher light lead (left)
Speedometer cable
Wireharness
Flasher light lead (right)
Main switch lead
Pilot box lead
Brake hose
Front brake switch lead
Handlebar switch lead (right)
lID
[QJ 10
[Q] Pass the throttle cable inside
of the clutch cable.
Pass the wireharness between
the under bracket and the
front fender.
[] Align the locating tape on the
wireharness with the headlight
stay.
ffiJ
-8-
________________________
CA
__
BL_E_R_O_U_T_IN_G
__
CD
Horn lead
~ Cable guide
@ Starter cable
@ Ignition coil
(j)
@
@
@
@
@
@
@
@
@
@
Band
Clamp
Fuel pipe
Air vent pipe
Overflow pipe
Clamp
Air cleaner
Drain pipe
Sidestand switch lead
Sidestand switch
Crankcase breather hose
Flywheel magneto lead
Seat pillar (left)
Clamp
Overflow pipe
@
@
@
<lID
@
IAl
-9-
lID
[g
[Q]
~
[]
[g]
[8]
IT]
sPEC~1
This band has slack within interference (Do not contact the
engine.)
Guide (engine side)
To engine
To start motor
Clamp the brake hose.
Clamp the brake hose and the
speedometer cable with the
band.
Clamp the brake hose to the
cable holder and pass the meter cable through the clamp.
Pass the brake hose inside and
the
meter
cable
outside
through the guide.
_______________________C_A_B_L_E_R_O_U_TI_N_G_lsPEC[~[
CD
Band
@ Flasher relay
(j)
@
@
(jJ)
@
@
@
@
@
@
@ Guide
@
@
~
ffil
[9
[QJ
-10 -
CABLE ROUTING
CD
Rectifier/regulator
ISPEC Ig-I
@ Band
seat pillar L.
CID Clamp
@ Rear flasher light lead (right)
@ Clamp
Taillight lead
Band
Neutral relay
-11 -
GENERAL INFORMATION
~ GEN
INFO
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The Vehicle Identification Number (VIN) CD is
stamped into the right side of the steering
head.
Vehicle Identification Number:
TTR225ULC
USA9C6CG04W
Calif. 9C6CG04Y
Can. 9C6CG04W
()X0000101
()X0000801
()XOOOOS01
TTR22SM/MC
USA 9C6G043
Calif. 9C6G04Y
( )Y0000101
( )Y0001301
GENERAL SPECIFICATIONS
Model:
TTR225ULC
TTR225M/MC
9C6CG04W( )XOOO0101
9C6CG04Y ( )XOOO0801
9C6CG04W( )XOOO0501
Dimensions:
Overall Length
Overall Width
Overall Height
Seat Height
Wheelbase
Minimum Ground Clearance
2,070mm
820mm
1,160mm
855mm
1,350mm
285mm
(81.5")
(32.2")
(45.7")
(33.6")
(53.1 ")
(11.2")
Basic Weight:
With oil and full fuel tank
126 kg
(278Ib)
1,900mm
(74.8")
Engine:
Engine Type
Cylinder Arrangement
Displacement
Bore x Stroke
Compression Ratio
Compression Pressure Standard
Starting System
Lubrication System:
Type
Engine Oil Type
Oil Capacity:
Periodic Oil Change
With Oil Filter Replacement
Total Amount
Air Filter:
Type
TBA
TBA
TBA
Wet Sump
Yamalube 4, SAE 20W40 type SE/SF motor oil or
SAE 10W30 type SE/SF motor oil
Wet-type element
GENERAL SPECIFICATIONS
Model:
Fuel:
Type
Fuel Tank Capacity
Fuel Reserve Amount
Carburetor:
Type/Quantity
Manufacturer
Spark Plug:
Type/Plug Gap/Manufacturer
TTR225ULC, MIMC
Unleaded Fuel Recommended (USA)
Regular Unleaded Gasoline (CON)
10L (2.2 Imp gal, 2.64 U.S. gal.)
1.8L (.39 Imp gal, .47 U.S. gal)
BST34/1 pc.
Mikuni
DR8EAlO.6-0.7mm
NGK
X24ESR-U/0.6-0.7mm
Nippondenso
(0.02-0.03")
(0.02-0.03")
Clutch:
Type
Transmission:
Type
Operation
Primary Reduction System
Primary Reduction Ratio
Secondary Reduction System
Secondary Reduction Ratio
Gear Ratio
1st
2nd
3rd
4th
5th
6th
Chassis:
Frame Type
Caster Angle
Trail
Diamond
26.5
102mm (4.0")
Tire:
Front
Rear
With tube
80/100-21
Pirelli
(51PMT21)
With tube
100/100-18
Pirelli
(59PMT21 )
Type
Size
Manufacture (Type)
GENERAL SPECIFICATIONS
Model:
TTR225ULC, MIMC
Brake:
Front Brake Type
Front Brake Operation
Rear Brake Type
Rear Brake Operation
Suspension:
Front
Rear
Telescopic Fork
Swingarm (new monocross)
Shock Absorber:
Front
Rear
Coil Coil -
Wheel Travel:
Front
Rear
225mm (8.9")
190mm (7.5")
Electrical:
Ignition System
Genertor System
Battery Type
Battery Capacity
CDI
AC Magneto Generator
HS7B-B
12V,7Ah
SPECIFICATIONS
MAINTENANCE SPECIFICATIONS -
ENGINE
TIR225LJLC, M/MC
Model:
Cylinder Head:
<Warp Limit>
<0.03mm (0.0012"
*Lines indicate straightedge measurement.
Cylinder:
Bore size
<Warp limit>
Measuring point @
Camshaft:
Drive Method
Camshaft Outside Diameter
Shaft-to-Cap Clearnace
Cam Dimensions
Intake "A"
"8"
69.970-70.020mm (2.7547-2.7567")
<70.1 mm (2.76"
40mm (1.6")
Chain Drive (left)
24.960-24.980mm (0.9827-0.9835")
0.020-0.061 mm (0.0008-0.0024")
tI\-"+r.....
__
-r-
36.51-36.61mm (1.437-1.441")
30.10-30.20mm (1.185-1.189")
6.50-6.62mm (0.256-0.261")
36.51-36.61 mm (1.437-1.441")
30.15-30.25mm (1.187-1.191")
6.50-6.62mm (0.256-0.261")
<0.03mm (0.0012"
"e"
Exhaust "A"
"8"
"G"
<Camshaft Runout Limit>
Cam Chain:
Cam Chain Type
Number of Links
Cam Chain Adjustment Method
DID25SH
104 Links
Automatic
12.000-12.018mm (0.472-0.473")
11.981-11.991 mm (0.4717-0.4721")
0.009-0.037mm (0.0004-0.0015")
0.05-0.09mm (0.002-0.004")
0.15-0.19mm (0.006-0.007")
33.9-34.1 mm (1.33-1.34")
3.68mm (0.145")
0.9-1.1 mm (0.03-0.04")
0.8-1.2mm (0.03-0.05")
MAINTENANCE SPECIFICATIONS -
ENGINE
Model:
TTR225ULC, MIMC
Exhaust:
"A" Head Diameter
"8" Face Width
"C" Seat Width
"0" Margin Thickness
28.4-28.6mm (1.12-1.13")
3.68mm (0.145")
0.9-1.1 mm (0.03-0.04")
0.8-1.2mm (0.031-0.050")
5.975-5.990mm (0.2352-0.2358")
5.960-5.975mm (0.2346-0.2352")
6.000-6.012mm (0.2362-0.2367")
6.000-6.012mm (0.2362-0.2367")
0.010-0.037mm (0.0004-0.0015")
0.025-0.052mm (0.0010-0.0020")
<0.010mm (0.0004"
0.9-1.1 mm (0.03-0.04")
0.9-1.1 mm (0.03-0.04")
Valve Spring:
Free Length:
Intake
Exhaust
Set Length (Valve Closed)
Intake
Exhaust
Direction of Winding
(Top View)
Inner Spring
Outer Spring
36.17mm (1.424")
36.17mm (1.424")
36.63mm (1.442")
36.63mm (1.442")
30.5mm (1.20")
30.5mm (1.20")
32.0mm (1.26")
32.0mm (1.26")
Counterclockwise
Clockwise
c
<Tilt Limit>:
Intake
Exhaust
<2.5/1.6mm (0.063"
<2.5/1.6mm (0.063"
<2.5/1.6mm (0.063"
<2.5/1.6mm (0.063"
SPECIFICATIONS
MAINTENANCE SPECIFICATIONS -
I~f iSPECd
ENGINE
Model:
TTR225ULC, MIMC
Piston:
Piston Size "0"
Measuring Point "H"
Oversize 2nd
Oversize 4th
69.925-69.975mm (2.7530-2.7549")
4.0mm (0.16")
70.50mm (2.776")
71.00mm (2.795")
0.5mm (0.02")
Intake Side
0.035-0.055mm (0.0014-0.0022")
<0.10mm (0.004"
Piston Off-set
Piston Off-set Direction
Piston-to-Cylinder Clearance
<Limit>
Piston Ring:
Type:
Top Ring
2nd Ring
Dimensions (BxT):
Top Ring
2nd Ring
Barrel
Taper
SdJs
~I_DB
I..
Oil Ring
B=1.2mm (0.05")
T=2.8mm (0.11")
B=1.2mm (0.05")
T =2.8mm (0.11")
.1
~]B
I..
B=2.5mm (0.10")
T =2.8mm (0.11")
.1
Crankshaft:
Crank Width "A"
<Runout Limit "C">
Big End Side
Clearance "0"
Small End
<Free Play Limit "F">
0.15-0.30mm (0.006-0.012")
0.15-0.30mm (0.006-0.012")
0.30-0.90mm (0.012-0.035")
0.03-0.07mm (0.001-0.003")
0.02-0.06mm (0.001-0.002")
--F
55.95-56.00mm (2.203-2.205")
<0.03mm (0.0012"
0.35-0.65mm (0.013-0.026")
<0.8mm (0.031"
Balancer:
Drive Method
Gear
MAINTENANCE SPECIFICATIONS -
ENGINE
TTR225ULC, MIMC
Model:
Clutch:
Friction Plate:
Thickness
Quantity
<Wear Limit>
Clutch Plate:
Thickness
Quantity
<Warp Limit>
Clutch Spring
Free Length
Quantity
Minimum Free Length
Clutch Housing:
Thrust Clearance
Clutch Release Method
<Push Rod Bending Limit>
2.90-3.10mm (0.114-0.122")
6 pcs.
<2.80mm (0.110"
1.50-1.70mm (0.059-0.067")
5 pcs.
<0.20mm (0.008"
37.3mm (1.47")
4 pcs.
35.3mm (1.39")
0.010-0.044mm (0.0004-0.0017")
Inner push, cam push
<0.05mm (0.02"
Transmission:
<Main Axle Runout Limit>
<Drive Axle Runout Limit>
<0.08mm (0.003"
<0.08mm (0.003"
Shifter:
Type
Carburetor:
10 Mark
Main Jet
Main Air Jet Size
Jet Needle
Needle Jet
Pilot Air Jet Size
Pilot Jet
Pilot Outlet
Bypass 1
Pilot Screw
Valve Seat Size
Starter Jet
Fuel Level
(with special tool)
Float Height
Engine Idle Speed
Intake Vacuum
(M.J.)
(M.A.J.)
(J.N.)
(N.J.)
(P.A.J.1 )
(P.A.J.2)
(P.J.)
(P.O.)
(B.P.1 )
(P.S.)
(V.S.)
(G.S.1 )
(G.S.2)
(F.L.)
(F.H.)
5FG1-00
#130
1.0
5DL27-1
0-1
#60
1.2
#40
0.85
0.8
2-1/8
2.0
65
0.8
11.0-12.0mm (0.43-0.47")
Below from the float chamber mating surface (front)
14.1-15.1 mm (0.56-0.59")
Below from the float chamber mating surface (front)
1,300-1 ,500 r/min
220-240 mmHg
8
SPECIFICATIONS
MAINTENANCE SPECIFICATIONS Model:
Lubrication System:
Oil Filter:
Type
Oil Pump:
Type
Tip Clearance
Side Clearance
Pressure Checking Location
11>7l sPEe d
ENGINE
TTR225ULC, M/MC
Cylinder Head
MAINTENANCE SPECIFICATIONS -
CHASSIS
Model:
TTR225ULC, M/MC
Steering System:
Bearing Type
No'/Size of Steel Balls (Upper)
Front Suspension:
Front Fork Travel
Front Spring Free Length
<Minimum Free Length>
Spring Rate
Stroke
(K1 )
(K2)
(K1 )
(K2)
Optional Spring
Oil Capacity
Oil Level
Oil Grade
Enclosed Air Pressure:
Standard
(Min.-Max.)
Rear Suspension:
Shock Absorber Travel
Spring Free Length
Fitting Length
Spring Rate
Stroke
Optional Spring
Enclosed Gas Pressure
Swing Arm:
<Free Play Limit>
Side Clearance
<Free Play Limit>
Front Wheel:
Type
Rim Size
Rim Material
<Rim Runout Limit>
Vertical
Lateral
225mm (8.9")
594.7mm (23.41")
588.8mm (23.18")
6.9 N/m (0.69 Kg/mm)
7.8 N/m (0.78 Kg/mm)
Zero-78.5mm (Zero-3.09")
78.5-230.0mm (3.09-9.06")
No
366cm 3 (12.8 Imp oz., 12.3 US oz)
140mm (5.5")
From top of inner tube fully compressed without
spring
Fork oil 10W or equivalent
Zero kPa (Zero kg/cm 2 , Zero psi)
Zero-40 kPa (Zero-O.4 kg/cm 2 , Zero-5.7 psi)
(K1)
(K1 )
72mm (2.8")
189mm (7.4")
174mm (6.9")
67.2 N/mm (6.85 kg/mm)
Zero-94mm (Zero-3.7")
No
1961 kPa (20kg/cm 2 , 284 psi)
<1.0mm (0.04" at swing arm end
Move swing arm end side to side.
0.4-0.7mm (0.02-0.03") at swing arm pivot
<1.0mm (0.04" at swing arm pivot
Spoke wheel
1.85 x 21
Steel
<2.0mm (0.08"
<2.0mm (0.08"
10
SPECIFICATIONS
MAINTENANCE SPECIFICATIONS Model:
l)Vf ISPECiI
CHASSIS
TTR225ULC, MIMC
Rear Wheel:
Type
Rim Size
Rim Material
<Rim Runout Limit>
Vertical
Lateral
Spoke wheel
2.15 x 1B
Steel
<2.0mm (O.OB"
<2.0mm (O.OB"
Drive Chain:
Type/Manufacturer
Number of Links
Chain Slack
42BV2/DAIDO
127
35-45mm (1.3B-1.77")
Single
220mm (B.7")
3.5mm (0.14")
6.0mm (0.24")
<O.Bmm (0.03"
11 mm (0.4")
34.93mm (1.375")
DOT No.4 or DOT NO. 3
Leading, Trailing
130mm (5.11")
<131 mm (5.15"
4.0mm (0.16")
<2mm (O.OB"
36.5mm (1.43")
11
MAINTENANCE SPECIFICATIONS -
ELECTRICAL
Model:
TTR225ULC, MIMC
Voltage:
12V
Ignition System:
Ignition Timing (S.T.D.C.)
Advanced Timing (S.T.D.C.)
Advancer Type
9 at 1,400 r/min
31 /6,000 r/min
Electrical type
;;----
30
I
II;V
U
0
a:i
Cl
"E
20
:~c
VI
~/
10
+1
1$11/2100
.2
---
29.5
27"/4,250
I
I~,OOO
- -'""
---'
,/
I
I
9 /1,400
.2l
31/6,000
Ii
I
I
10
12
COl:
Unit Model/Manufacturer
Pickup Coil Resistance (Color)
Charging Coil Resistance (Color)
4JGNAMAHA
280-4200 at 20C (68F) W/L-W/R
600-900Q at 20C (68F) S/R-G/W
482-7080 at 20C (68F) G/L-G/W
Ignition Coil:
Model/Manufacturer
Primary Coil Resistance
Secondary Coil Resistance
Minimum Spark Gap
2JNNAMAHA
0.56-0.840 at 20C (68F)
5.68-8.52kQ at 20C (68F)
6.0mm (0.24")
Resin type
10kQ at 20C (68F)
Charging System:
Type
12
SPECIFICATIONS j PfjSPECII
MAINTENANCE SPECIFICATIONS -
ELECTRICAL
Model:
TTR225ULC, M/MC
A.C. Generator:
Model/Manufacturer
Charging Output
F4JGNAMAHA
14V, 1OA at S,OOO r/min
20
16
C
i'!
12
:;
"'""'
:;
:;
a
c.
I
2
10
12
Voltage Regulator/Rectifier:
Model/Manufacturer
Voltage Regulator:
Type
No Load Regulated Voltage
Rectifier:
Capacity
Battery:
Specific Gravity
HS7B-B/12V7 Ah
1.260
Starter Motor:
Model/Manufacturer
Output
Brush Overall Length
<Limit>
Commutator Diameter
<Limit>
Mica Undercut (Depth)
3RW1NAMAHA
0.4 kW
10.0mm (0.39")
<3.Smm (0.14"
22.0mm (0.87")
<21.0mm (0.83"
1.Smm (0.06")
Starter Relay
Model/Manufacturer
Amperage Rating
MSSD-191/HITACHI
100A
Circuit Breaker:
Type
Amperage for Individual Circuit x Qty:
Main
Reserve
Fuse
1SA/1 pc.
1SA/1 pc.
13
"'
INSP
Adjust.
AWARNING
14
Cold
Tire Pressure
Front
Off-Road Riding
Up to 90 kg
(198 Ib) load
100 kPa
100 kPa
(1.0kgf/cm 2 , (1.0kgf/cm 2 ,
15 psi)
15 psi)
Rear
CARBURETION
CARB
CARBURETION
CARBURETOR
CD Diaphragm Cover
Diaphragm Spring
Jet Needle Set
CD Diaphragm Assembly
Needle Jet
Pilot Air Jet
(j) Starter Plunger Assembly
Throttle Stop Screw
Float Pin
@ Float
@ Needle Valve Set
@ Main Jet
@ Pilot Jet
@ Pilot Screw
@ O-Ring
@ Diaphragm Assembly
(coasting enricher)
@ O-Ring
@ Cover Assembly
SPECIFICATIONS
10 MARK
5FG1-00 (USA-Except
for California)
5FG1-00 (USA-For
California)
5FG1-00 (CON)
#130
#40
SDL27-1
0-1
2-1/8
#130
#40
5DL27-1
0-1
2-1/8
~~
V
2 Nm
(0.2 m.kg, 1.4 ftlb)
15
~r---------'
2 Nm
(0.2 m.kg, 1.4 ftlb)
(!)~
CHASSIS
CHASSIS
FRONT WHEEL
CD
CD
Wheel Axle
Cotter Pin
Washer
Collar
Dust Cover
Oil Seal
Bearing
Spacer Collar
Front Wheel
@
@
@
@
@
@
Bearing
Gear Unit (Speedometer)
Washer
Nut
TIRE AIR PRESSURE (COLD):
Cable Band
Cold Tire Pressure
Front
Disc Cover
Off-Road Riding
100 kPa
(1.0kgf/cm 2 ,
15 psi)
Rear
100 kPa
(1.0kgf/cm 2 ,
15 psi)
A TIRE SIZE:
80/100-21
B RIM SIZE:
1.85 x 21
RIM RUNOUT LIMIT:
VERTICAL:
C
2.0 mm (0.08 in)
LATERAL:
2.0 mm (0.08 in)
WEAR LIMIT:
0.8 mm (0.03 in)
2 Nm
(0.2 m.kg. 1.4 ft.lb)
IB6202\
16
CHASSIS
CHASSIS
REAR WHEEL
CD Camshaft Lever
A
B
@ Spacer
@ Brake Rod
@ Compression Spring
@ Collar
@ Rear Wheel
TIRE AIR PRESSURE (COLD):
@ Bearing
Cold Tire Pressure
@ Oil Seal
Front
@ Dust Collar
Off-Road Riding
100 kPa
@) Cotter Pin
(1.0kgf/cm 2 ,
@WheelAxle
TIRE SIZE:
100/100-18
RIM SIZE:
15 psi)
Rear
100 kPa
(1.0kgf/cm 2 ,
15 psi)
2.15 x 18
17
AS
0~
CHASSIS
REAR WHEEL
REAR BRAKE
The following shows only the difference(s) from
the XT225.
Brake lining thickness:
4mm (0.16 in)
Wear limit:
2mm (0.08 in)
9. Inspect:
Brake drum inner surface
Oil/Scratches ~ Replace.
Oil
Scratches
10. Measure:
Brake drum inside diameter
Out of specification ~ Replace.
Brake drum inside diameter:
STD: 130mm (5.11 in)
ASSEMBLY
Rear Brake
Install the camshaft and the pivot pin lightly with grease. Wipe off the excess grease.
18
CHASSIS
AS~
ASSEMBLY
10. Install:
Dust Seal CD
Use the fork seal driver weight @ and
adapter .
Fork seal driver weight:
YM-33963
90890-01367
Adapter
36mm (1.42 in):
YM-08010
90890-01370
11. Fill:
Front fork
Each fork:
366cm 3 (12.8 Imp oz, 12.3 US oz)
Fork oil 10W or equivalent
After filling, slowly pump the
fork up and down to distribute oil.
o
Oil level :
140mm (5.5 in)
From the top of inner fork tube
fully compressed without spring.
CD
12. Install:
Fork spring CD
Spring seat @
Stopper ring
19
0~
CHASSIS
CD Driven Sprocket
CD
Lock Washer
Chain Joint
Drive Chain
Sprocket Holder
Drive Sprocket
DRIVE CHAIN
B TYPE:
428V2
C
NO. OF LINKS:
127
DRIVE CHAIN SLACK:
35-45 mm 11.38-1.n in)
"
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20
ELECTRICAL ELEC
I53 II
ELECTRICAL COMPONENTS
CD Wire Harness
C.D.I. Unit
Neutral Relay
0) Fuse (Main)
Battery
BATTERY:
Capacity: 12V 7AH
Specific Gravity: 1.260
IGNITION COIL:
Primary Coil Resistance:
0.56-0.S4Q at 20C (6S0F)
Secondary Coil Resistance:
5.6S-S.52kQ at 20C (6S0F)
~
~~
21
II Ie I
ELEC
ELECTRICAL
n
*
Step 1:
Tester
Tester
Step 2:
Tester
Tester
(+) lead
(-) lead
(+) lead
(-) lead
-7
-7
-7
-7
OUT OF SPECIFICATION
,
Charge coil is faulty, replace charge coil assembly.
MEET SPECIFICATION
22
--7
--7
OUT OF SPECIFICATION
Jl
MEET SPECIFICATION
POOR CONNECTION
, ,
Correct.
Jl
CORRECT
23
SWITCH
CLUTCH
SWITCH
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REGULATOR
0
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ON
COLOR CODE
MAIN
SWITCH
R LJB LlY
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LOCK
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WHITE
ORANGE
Br
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BROWN
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GREEN
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