M.s.cygnus Z125

SERVICE MANUAL
XA125
2BK-F8197-E1
EAS20040
XA125
SERVICE MANUAL
©2012 by Yamaha Motor Co., Ltd.
First edition, November 2012
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential person-
al injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could

WARNING result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

EAS20091
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
4
2
5
6
EAS20101
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

BF
Special tool B Wheel bearing grease
Tightening torque LS Lithium-soap-based grease

T.
R.
Wear limit, clearance M Molybdenum disulfide grease
Engine speed S Silicone grease
Electrical data Apply locking agent (LOCTITE®).

LT
Engine oil New Replace the part with a new one.

E
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
FUEL SYSTEM 6
ELECTRICAL SYSTEM 7
TROUBLESHOOTING 8
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1
1
IMPORTANT INFORMATION ......................................................................... 1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2
REPLACEMENT PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-2
BEARINGS AND OIL SEALS .................................................................... 1-3
CIRCLIPS ..................................................................................................1-3
CHECKING THE CONNECTIONS ..................................................................1-4
SPECIAL TOOLS ............................................................................................ 1-6

IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.
EAS20150
MODEL LABEL
The model label “1” is affixed to the storage com-
partment. This information will be needed to or-
der spare parts.
EAS20160
ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the
side part of the left rear section of the engine.
1-1
IMPORTANT INFORMATION
EAS20180
EAS20190
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS20210
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-6.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER

PINS
4. During disassembly, clean all of the parts and After removal, replace all lock washers/plates
place them in trays in the order of disassem- “1” and cotter pins. After the bolt or nut has been
bly. This will speed up assembly and allow for tightened to specification, bend the lock tabs
the correct installation of all parts. along a flat of the bolt or nut.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-2
EAS20230
BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
ECA13300
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-3
CHECKING THE CONNECTIONS
EAS20250
CHECKING THE CONNECTIONS Pocket tester

Check the leads, couplers, and connectors for 90890-03112
stains, rust, moisture, etc. Analog pocket tester
1. Disconnect: YU-03112-C
• Lead
• Coupler TIP
• Connector • If there is no continuity, clean the terminals.
2. Check: • When checking the wire harness, perform
• Lead steps (1) to (3).
• Coupler • As a quick remedy, use a contact revitalizer
• Connector available at most part stores.
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.
3. Check:
• All connections
Loose connection → Connect properly.
TIP
If the pin “1” on the terminal is flattened, bend it
up.
6. Check:
• Resistance
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
The resistance values shown were obtained at
4. Connect: the standard measuring temperature of 20 °C
• Lead (68 °F). If the measuring temperature is not 20
• Coupler °C (68 °F), the specified measuring conditions
• Connector will be shown.
TIP
Intake air temperature sensor re-
Make sure all connections are tight.
sistance
5. Check: 5.40–6.60 kΩ at 0 °C (32 °F)
• Continuity 290–390 Ω at 80 °C (176 °F)
(with the pocket tester)
1-4
CHECKING THE CONNECTIONS
1-5
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-4, 7-35, 7-37,
90890-03112 7-38, 7-41,
Analog pocket tester 7-42, 7-43,
YU-03112-C 7-44, 7-45,
7-46
Tappet adjusting tool 3-4

90890-01311
Six piece tappet set
YM-A5970
YM-A5970
ø8 ø9 ø10
ø3 ø4
Digital tachometer 3-5, 3-6, 3-8,
90890-06760 7-45
YU-39951-B
Pocket tester 3-6

90890-03132
Timing light 3-8

90890-03141
YU-03141
Compression gauge 3-9

90890-03081
Engine compression tester
YU-33223
1-6
SPECIAL TOOLS
Reference
pages
Compression gauge extension S 3-9
90890-03195
37
Steering nut wrench 3-18, 3-19

90890-01403
Exhaust flange nut wrench
YU-A9472
Ring nut wrench 3-19, 4-43

90890-01268
Spanner wrench
YU-01268
T-handle 4-36, 4-38

90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Damper rod holder 4-36, 4-38

90890-01294
Damping rod holder set
YM-01300
YM-01300
Fork seal driver weight 4-38

90890-01367
Replacement hammer
YM-A9409-7
YM-A9409-7/YM-A5142-4
1-7
SPECIAL TOOLS
Reference
pages
Fork seal driver attachment (ø30) 4-38
90890-01400
Yamaha bond No. 1215 5-10, 5-55

90890-85505
(Three Bond No.1215®)
Slide hammer bolt 5-13, 5-15,

90890-01085 5-16
Slide hammer bolt 8 mm
YU-01083-2
Weight 5-13
90890-01084
YU-01083-3
YU-01083-3
Valve spring compressor 5-18, 5-23

90890-04019
YM-04019
Valve spring compressor attachment 5-18, 5-23

90890-04108
Valve spring compressor adapter 22 mm
YM-04108
Valve guide remover (ø4.5) 5-19

90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide installer (ø4.5) 5-19

90890-04117
Valve guide installer (4.5 mm)
YM-04117
1-8
SPECIAL TOOLS
Reference
pages
Valve guide reamer (ø5) 5-19
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
Piston pin puller set 5-25

90890-01304
Piston pin puller
YU-01304
YU-01304
Rotor holding tool 5-30, 5-36,

90890-01235 5-41
Universal magneto & rotor holder
YU-01235
Flywheel puller 5-30

90890-01189
YM-01189
Sheave holder 5-36, 5-41

90890-01701
Primary clutch holder
YS-01880-A
Locknut wrench 5-36, 5-41

90890-01348
YM-01348
1-9
SPECIAL TOOLS
Reference
pages
Clutch spring holder 5-37, 5-40
90890-01337
Universal clutch compressor holder
YM-33285
Clutch spring holder arm 5-37, 5-40

90890-01464
Compressor holder adapter
YM-33285-6
Oil seal guide (ø41) 5-40

90890-01396
Digital circuit tester 5-48

90890-03174
Model 88 Multimeter with tachometer
YU-A1927
Vacuum/pressure pump gauge set 6-2, 6-14

90890-06756
Mityvac brake bleeding tool
YS-42423
Fuel level gauge 6-8

90890-01312
YM-01312-A
Ignition checker 7-43

90890-06754
Oppama pet-4000 spark checker
YM-34487
1-10
SPECIAL TOOLS
1-11
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-9
ELECTRICAL SPECIFICATIONS .................................................................2-12
TIGHTENING TORQUES .............................................................................. 2-14

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-14
ENGINE TIGHTENING TORQUES......................................................... 2-15
CHASSIS TIGHTENING TORQUES.......................................................2-18
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-21

ENGINE................................................................................................... 2-21
CHASSIS.................................................................................................2-22
LUBRICATION SYSTEM DIAGRAMS .......................................................... 2-23

LUBRICATION DIAGRAMS .................................................................... 2-23
CABLE ROUTING ......................................................................................... 2-25

GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model 2BK1 (For air induction system models)
2BK2 (Except for air induction system models)
Dimensions
Overall length 1850 mm (72.8 in)
Overall width 670 mm (26.4 in)
Overall height 1080 mm (42.5 in)
Seat height 760 mm (29.9 in)
Wheelbase 1250 mm (49.2 in)
Ground clearance 95 mm (3.74 in)
Minimum turning radius 1800 mm (70.9 in)
Weight
Curb weight 113 kg (249 lb) (For air induction system
models)
111 kg (245 lb) (Except for air induction system
models)
Maximum load 153 kg (337 lb)
2-1
ENGINE SPECIFICATIONS
EAS20290
Engine
Engine type Air cooled 4-stroke, SOHC
Displacement 125 cm³ (7.63 cu.in)
Cylinder arrangement Forward-inclined single cylinder
Bore × stroke 51.5 × 60.0 mm (2.03 × 2.36 in)
Compression ratio 9.50 : 1
Standard compression pressure (at sea level) 1200 kPa/600 r/min (12.0 kgf/cm²/600 r/min,
170.6 psi/600 r/min)
Minimum–maximum 1040–1340 kPa (10.4–13.4 kgf/cm², 147.9–
190.5 psi)
Starting system Electric starter and kickstarter
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 7.3 L (1.93 US gal, 1.61 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 20W-40 or 10W-30
Recommended engine oil grade API service SE type or higher, JASO standard
MA
Engine oil quantity
Quantity (disassembled) 1.20 L (1.27 US qt, 1.06 Imp.qt)
Periodic oil change 1.00 L (1.06 US qt, 0.88 Imp.qt)
Final transmission oil

Type SAE 85W-140 (GL5)
Quantity (disassembled) 0.15 L (0.16 US qt, 0.13 Imp.qt)
Periodic oil change 0.13 L (0.14 US qt, 0.11 Imp.qt)
Oil filter
Oil filter type Centrifugal
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.150 mm (0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.25 mm (0.0098 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.10 mm (0.0024–0.0039 in)
Limit 0.17 mm (0.0067 in)
Rotor thickness 7.96–7.98 mm (0.3134–0.3142 in)
Spark plug(s)
Manufacturer/model NGK/CR7E
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
2-2
Cylinder head
Combustion chamber volume 10.40–10.80 cm³ (0.63–0.66 cu.in)
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Drive system Chain drive (left)
Camshaft lobe dimensions
Intake A 25.881–25.981 mm (1.0189–1.0229 in)
Limit 25.781 mm (1.0150 in)
Intake B 21.195–21.295 mm (0.8344–0.8384 in)
Limit 21.095 mm (0.8305 in)
Exhaust A 25.841–25.941 mm (1.0174–1.0213 in)
Limit 25.741 mm (1.0134 in)
Exhaust B 21.050–21.150 mm (0.8287–0.8327 in)
Limit 20.950 mm (0.8248 in)
AA
B
B
Camshaft runout limit 0.015 mm (0.0006 in)
Timing chain
Model/number of links 4S55/88
Tensioning system Automatic
Rocker arm/rocker arm shaft

Rocker arm inside diameter 10.000–10.015 mm (0.3937–0.3943 in)
Limit 10.030 mm (0.3949 in)
Rocker arm shaft outside diameter 9.981–9.991 mm (0.3930–0.3933 in)
Limit 9.950 mm (0.3917 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.034 mm (0.0004–0.0013 in)
Limit 0.080 mm (0.0032 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.08–0.12 mm (0.0032–0.0047 in)
2-3
Exhaust 0.13–0.17 mm (0.0051–0.0067 in)

Valve dimensions
Valve head diameter A (intake) 22.90–23.10 mm (0.9016–0.9094 in)
Valve head diameter A (exhaust) 19.90–20.10 mm (0.7835–0.7913 in)
A
Valve face width B (intake) 1.200–2.470 mm (0.0472–0.0972 in)
Valve face width B (exhaust) 1.620–2.890 mm (0.0638–0.1138 in)
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Limit 1.60 mm (0.06 in)
Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.60 mm (0.06 in)
Valve margin thickness D (intake) 0.70 mm (0.0276 in)

Valve margin thickness D (exhaust) 1.00 mm (0.0394 in)
Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in)

Limit 4.945 mm (0.1947 in)
Valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in)
Limit 4.930 mm (0.1941 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Limit 5.053 mm (0.1988 in)
Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in)
Limit 5.053 mm (0.1988 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Free length (intake) 35.44 mm (1.40 in)
2-4
Limit 33.67 mm (1.33 in)

Free length (exhaust) 35.44 mm (1.40 in)
Limit 33.67 mm (1.33 in)
Installed length (intake) 24.10 mm (0.95 in)
Installed length (exhaust) 24.10 mm (0.95 in)
Installed compression spring force (intake) 146–168 N (14.89–17.13 kgf, 32.83–37.77 lbf)
Installed compression spring force (exhaust) 146–168 N (14.89–17.13 kgf, 32.83–37.77 lbf)
Spring tilt (intake) 2.5°/1.5 mm (0.059 in)
Spring tilt (exhaust) 2.5°/1.5 mm (0.059 in)
Cylinder
Bore 51.500–51.510 mm (2.0276–2.0279 in)
Wear limit 51.610 mm (2.0319 in)
Measuring point H 45.0 mm (1.77 in)
Piston
Piston-to-cylinder clearance 0.020–0.045 mm (0.0008–0.0018 in)
Limit 0.15 mm (0.0059 in)
Diameter D 51.465–51.480 mm (2.0262–2.0268 in)
Height H 5.0 mm (0.20 in)
H
D
Offset 0.50 mm (0.0197 in)

Offset direction Intake side
Piston pin bore inside diameter 13.002–13.013 mm (0.5119–0.5123 in)
Limit 13.043 mm (0.5135 in)
Piston pin outside diameter 12.996–13.000 mm (0.5117–0.5118 in)
Limit 12.976 mm (0.5109 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.017 mm (0.0001–0.0007 in)
Limit 0.067 mm (0.0026 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 1.00 × 2.10 mm (0.04 × 0.08 in)
B
T
End gap (installed) 0.10–0.20 mm (0.0039–0.0079 in)

Limit 0.45 mm (0.0177 in)
2-5
Ring side clearance 0.020–0.080 mm (0.0008–0.0032 in)

Limit 0.130 mm (0.0051 in)
2nd ring
Ring type Taper
B
T

Limit 0.65 mm (0.0256 in)
Limit 0.120 mm (0.0047 in)
Oil ring
B
T

Connecting rod
Small end inside diameter 13.015–13.028 mm (0.5124–0.5129 in)
Crankshaft
Width A 44.80–44.85 mm (1.764–1.766 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.10–0.30 mm (0.004–0.012 in)
Limit 1.0 mm (0.039 in)
Big end radial clearance E 0.010–0.025 mm (0.0004–0.0010 in)
C C
E
D
Clutch
Clutch type Dry, centrifugal automatic
Automatic centrifugal clutch

Clutch shoe thickness 2.0 mm (0.08 in)
Limit 1.0 mm (0.04 in)
Clutch shoe spring free length 28.2 mm (1.11 in)
Clutch housing inside diameter 120.0–120.2 mm (4.724–4.732 in)
Limit 120.6 mm (4.748 in)
Compression spring free length 94.3 mm (3.71 in)
Limit 89.6 mm (3.53 in)
2-6
Spring quantity 3 pcs

Weight outside diameter 19.9–20.1 mm (0.783–0.791 in)
Limit 19.5 mm (0.768 in)
Clutch-in revolution 3050–3650 r/min
Clutch-stall revolution 5300–6300 r/min
V-belt
V-belt width 21.6 mm (0.85 in)
Limit 19.4 mm (0.76 in)
Transmission
Transmission type V-belt automatic
Primary reduction ratio 1.000
Final drive Gear
Secondary reduction ratio 7.795 (40/15 × 38/13)
Gear ratio 2.470–0.820 :1
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Main axle assembly width 41.26–41.46 mm (1.624–1.632 in)
Kickstarter
Kickstarter type Ratchet
Kick clip friction force P 0.70–2.00 N (0.07–0.20 kgf, 0.16–0.45 lbf)
Air filter
Air filter element Oil-coated paper element
Carburetor
Type × quantity NCV24 × 1
ID mark 2BK1 00 (For air induction system models)
2BK2 10 (Except for air induction system
models)
Main jet #105
Main air jet 1.5 (For air induction system models)
1.0 (Except for air induction system models)
Jet needle NPKK (For air induction system models)
NQAA (Except for air induction system models)
Needle jet N426
Pilot outlet 0.9
Slow jet #38 (For air induction system models)
#38 × #38 (Except for air induction system
models)
Bypass 1 0.7
Bypass 2 0.7
Bypass 3 0.7
Bypass 4 0.7
Pilot screw turns out 2 (For air induction system models)
1–7/8 (Except for air induction system models)
Valve seat size 1.6
Starter jet 1 #38 (For air induction system models)
#40 (Except for air induction system models)
Fuel level A (using fuel level gauge) 6.6–7.6 mm (0.26–0.30 in) (below the float
chamber mating surface)
2-7
Idling condition
Engine idling speed 1550–1750 r/min
CO% (air induction system ON) 0.0–3.0 %
CO% (air induction system OFF) 2.0–8.0 %
Intake vacuum 26.7–32.0 kPa (200–240 mmHg, 7.9–9.4 inHg)
Oil temperature 70.0–80.0 °C (158.00–176.00 °F)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-8
CHASSIS SPECIFICATIONS
EAS20300
Chassis
Frame type Backbone
Caster angle 27.00°
Trail 75 mm (3.0 in)
Front wheel
Wheel type Cast wheel
Rim size J10 × 2.15
Rim material Aluminum
Wheel travel 80.0 mm (3.15 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Rear wheel
Wheel type Cast wheel
Rim size J10 × MT2.50
Rim material Aluminum
Wheel travel 65.0 mm (2.56 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Front tire
Type Tubeless
Size 3.50–10 51J (For air induction system models)
100/90–10 56J (Except for air induction system
models)
Manufacturer/model CHENG SHIN/S922S (For air induction system
models)
CHENG SHIN/C922 (Except for air induction
system models)
Wear limit (front) 1.0 mm (0.04 in)
Rear tire
Type Tubeless
Size 3.50–10 51J (For air induction system models)
100/90–10 56J (Except for air induction system
models)
Manufacturer/model CHENG SHIN/S6007 (For air induction system
models)
CHENG SHIN/C940 (Except for air induction
system models)
Wear limit (rear) 1.0 mm (0.04 in)
Tire air pressure (measured on cold tires)

Loading condition 0–83 kg (0–183 lb)
Front 175 kPa (1.75 kgf/cm², 25 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
Loading condition 83–153 kg (183–337 lb)
Front 175 kPa (1.75 kgf/cm², 25 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
2-9
Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter × thickness 180.0 × 4.0 mm (7.09 × 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 5.3 mm (0.21 in)
Brake pad lining thickness (outer) 5.3 mm (0.21 in)
Master cylinder inside diameter 11.00 mm (0.43 in)
Caliper cylinder inside diameter 33.34 mm (1.31 in)
Specified brake fluid DOT 3 or 4
Rear brake
Type Drum brake
Operation Left hand operation
Rear brake lever free play 10.0–20.0 mm (0.39–0.79 in)
Rear drum brake
Drum brake type Leading, trailing
Brake drum inside diameter 110.0 mm (4.33 in)
Limit 111.0 mm (4.37 in)
Lining thickness 4.0 mm (0.16 in)
Shoe spring free length 52.0 mm (2.05 in)
Shoe spring free length 2 48.0 mm (1.89 in)
Steering
Steering bearing type Ball bearing
Center to lock angle (left) 47.5°
Center to lock angle (right) 47.5°
No./size of steel balls
(Upper) 19 pcs/4.76 mm (0.187 in)
(Lower) 16 pcs/6.35 mm (0.250 in)
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 80.0 mm (3.15 in)
Fork spring free length 227.0 mm (8.94 in)
Limit 222.0 mm (8.74 in)
Fork spring installed length 223.0 mm (8.78 in)
Spring rate K1 8.70 N/mm (0.89 kgf/mm, 49.68 lbf/in)
Spring stroke K1 0.0–50.0 mm (0.00–1.97 in)
Inner tube outer diameter 30.0 mm (1.18 in)
Optional spring available No
Recommended oil Fork oil 10W or equivalent
Quantity 83.5 cm³ (2.82 US oz, 2.94 Imp.oz)
Level 84.6 mm (3.33 in)
2-10
Rear suspension
Type Unit swing
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 65.0 mm (2.56 in)
Spring free length 203.0 mm (7.99 in)
Spring installed length 194.4 mm (7.65 in)
Optional spring available No
2-11
ELECTRICAL SPECIFICATIONS
EAS20310
Voltage
System voltage 12 V
Ignition system
Ignition system DC CDI
Advancer type Electrical
Ignition timing (B.T.D.C.) 5.0°/1650 r/min
DC. CDI
Pickup coil resistance 248–372 Ω
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 0.32–0.48 Ω
Secondary coil resistance 5.68–8.52 k.Ω
Spark plug cap

Material Resin
Resistance 10.0 k.Ω
AC magneto
Standard output 14.0 V, 140 W at 5000 r/min
Stator coil resistance 0.480–0.720 Ω
Rectifier/regulator
No load regulated voltage 14.1–14.9 V
Rectifier capacity 10.0 A
Battery
Model GTX7A-BS/YTX7A-BS
Voltage, capacity 12 V, 6.0 Ah
Manufacturer GS/YUASA
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity

Headlight 12 V, 35.0 W/35.0 W × 1
Auxiliary light 12 V, 5.0 W × 1
Tail/brake light 12 V, 5.0 W/21.0 W × 1
Front turn signal light 12 V, 10.0 W × 2
Rear turn signal light 12 V, 10.0 W × 2
Meter lighting LED (For air induction system models)
12 V, 3.4 W × 2 (Except for air induction system
models)
2-12
Indicator light
Turn signal indicator light 12 V, 3.0 W × 1 (For air induction system
models)
12 V, 1.7 W × 2 (Except for air induction system
models)
High beam indicator light LED (For air induction system models)
12 V, 1.7 W (Except for air induction system
models)
Engine trouble warning light LED (For air induction system models)
Electric starting system

System type Constant mesh
Starter motor
Power output 0.30 kW
Armature coil resistance 0.0306–0.0374 Ω
Brush overall length 10.0 mm (0.39 in)
Limit 3.50 mm (0.14 in)
Brush spring force 5.52–8.28 N (563–844 gf, 19.87–29.80 oz)
Commutator diameter 22.0 mm (0.87 in)
Limit 21.0 mm (0.83 in)
Mica undercut (depth) 1.50 mm (0.06 in)
Starter relay
Amperage 100.0 A
Coil resistance 3.60–4.40 Ω
Horn
Horn type Plane
Quantity 1
Maximum amperage 1.5 A
Turn signal relay

Relay type Full transistor
Turn signal blinking frequency 75–95 cycles/min
Fuel sender unit

Sender unit resistance (full) 4.0–10.0 Ω
Sender unit resistance (empty) 90.0–100.0 Ω
Fuses
Main fuse 15.0 A
Spare fuse 15.0 A
2-13
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening
A (nut) B (bolt) torques
Nm m·kg ft·lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-14
TIGHTENING TORQUES
EAS20340
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Cylinder head nut M8 4 22 Nm (2.2 m·kg, 16 ft·lb) E
Spark plug M10 1 13 Nm (1.3 m·kg, 9.4 ft·lb)

Cylinder head bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb)
Cylinder bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Cylinder head stud bolt (intake
manifold) (For air induction sys- M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
tem models)
Cylinder head stud bolt (exhaust
M8 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
pipe)
Cylinder head breather assem-
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
bly bolt
Cylinder head stud bolt (air in-
duction system pipe) (For air in- M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
duction system models)
Engine oil check bolt (For air in-
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Engine oil check bolt (Except for
M10 1 20 Nm (2.0 m·kg, 14 ft·lb)
air induction system models)
Tappet cover M45 2 18 Nm (1.8 m·kg, 13 ft·lb)
Camshaft retainer bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Timing chain guide (intake side)
M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
bolt
Valve clearance adjusting screw
M5 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
locknut
Camshaft sprocket bolt M8 1 29 Nm (2.9 m·kg, 21 ft·lb)
Yamaha
bond
No.1215
Timing chain tensioner assembly
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) (Three
bolt
bond
No.1215
®)
Timing chain tensioner assembly
M8 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
cap bolt
Air shroud (right side) tapping
M6 4 2 Nm (0.2 m·kg, 1.4 ft·lb)
screw
Air shroud (right side) screw M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
Air shroud (right side) bolt (For
M6 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
Air shroud (right side) bolt (Ex-
cept for air induction system M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
models)
Fan screw M6 3 6 Nm (0.6 m·kg, 4.3 ft·lb)
2-15
TIGHTENING TORQUES
Thread
size
Oil pump assembly screw M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
Engine oil drain plug M35 1 31 Nm (3.1 m·kg, 22 ft·lb)
Intake manifold nut M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
Air filter case assembly screw M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
Air filter case cover screw M6 7 6 Nm (0.6 m·kg, 4.3 ft·lb)
Air induction system pipe nut (For
M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb)
Exhaust pipe nut M8 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
Muffler bolt M8 2 31 Nm (3.1 m·kg, 22 ft·lb)
Muffler protector screw M6 3 9 Nm (0.9 m·kg, 6.5 ft·lb) LT
Reed valve assembly bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Air induction system pipe bolt
M6 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
(For air induction system models)
Crankcase bolt M6 8 12 Nm (1.2 m·kg, 8.7 ft·lb)
V-belt case cover bolt M6 10 10 Nm (1.0 m·kg, 7.2 ft·lb)
Transmission case cover bolt M6 5 12 Nm (1.2 m·kg, 8.7 ft·lb)
Oil pump cover bolt M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb)
Crankcase stud bolt M8 4 12 Nm (1.2 m·kg, 8.7 ft·lb)
Transmission oil drain bolt M8 1 23 Nm (2.3 m·kg, 17 ft·lb)
Engine oil drain bolt M12 1 20 Nm (2.0 m·kg, 14 ft·lb)
V-belt case air filter element
M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
guide screw
Plate bolt M6 4 8 Nm (0.8 m·kg, 5.8 ft·lb)
V-belt case air duct screw M6 3 6 Nm (0.6 m·kg, 4.3 ft·lb)
Idle gear shaft holder screw M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
Kickstarter pedal bolt M8 1 23 Nm (2.3 m·kg, 17 ft·lb)
Clutch housing nut M14 1 60 Nm (6.0 m·kg, 43 ft·lb)
Primary sheave nut M12 1 54 Nm (5.4 m·kg, 39 ft·lb)
Secondary sheave nut M36 1 90 Nm (9.0 m·kg, 65 ft·lb)
Starter motor assembly bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
AC magneto rotor nut M12 1 69 Nm (6.9 m·kg, 50 ft·lb)
Stator coil screw M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)
Pickup coil bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Ignition coil screw M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
2-16
TIGHTENING TORQUES
Cylinder head tightening sequence:
2-17
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES

Thread
size
Frame and engine bracket 2 M10 2 42 Nm (4.2 m·kg, 30 ft·lb)
Engine bracket 2 and engine
M10 1 55 Nm (5.5 m·kg, 40 ft·lb)
bracket 1
Engine bracket 1 and engine M10 2 48 Nm (4.8 m·kg, 35 ft·lb)
Engine bracket 1, engine and
M10 2 48 Nm (4.8 m·kg, 35 ft·lb)
centerstand
Centerstand lock assembly and
M10 2 48 Nm (4.8 m·kg, 35 ft·lb) LT
engine bracket 1
Centerstand lock assembly cover M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Sidestand (bolt and nut) M8 1 19 Nm (1.9 m·kg, 13 ft·lb)
Sidestand (bolt and stand) M8 1 9 Nm (0.9 m·kg, 6.5 ft·lb)
Rear shock absorber assembly
M10 1 33 Nm (3.3 m·kg, 24 ft·lb)
upper nut
M8 1 18 Nm (1.8 m·kg, 13 ft·lb)
lower bolt
Rear fender and crankcase cover M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Steering shaft and ring nut M25 3 75 Nm (7.5 m·kg, 54 ft·lb) See TIP.
Handlebar nut M10 1 60 Nm (6.0 m·kg, 43 ft·lb)
Lower bracket pinch bolt M12 2 65 Nm (6.5 m·kg, 47 ft·lb) See TIP.
Front fork cap bolt M25 2 65 Nm (6.5 m·kg, 47 ft·lb) See TIP.
Damper rod assembly bolt M8 2 30 Nm (3.0 m·kg, 22 ft·lb) LT
Brake master cylinder and brake

M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
master cylinder holder
Brake master cylinder and brake
M10 1 30 Nm (3.0 m·kg, 22 ft·lb)
hose
Throttle cable holder and throttle
M5 1 4 Nm (0.4 m·kg, 2.9 ft·lb)
cable housing
Throttle cable housing screw M5 1 4 Nm (0.4 m·kg, 2.9 ft·lb)
Throttle cable assembly and car-
M5 2 5 Nm (0.5 m·kg, 3.6 ft·lb)
buretor
Horn and frame M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Ignition coil and frame M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rectifier/regulator and frame M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Main switch and frame M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Main switch and shutter M5 1 4 Nm (0.4 m·kg, 2.9 ft·lb)
Speedometer and speedometer
M12 1 5 Nm (0.5 m·kg, 3.6 ft·lb)
cable
Speedometer gear unit and
M12 1 4 Nm (0.4 m·kg, 2.9 ft·lb)
speedometer cable
Resin part (truss head tapping
— — 2 Nm (0.2 m·kg, 1.4 ft·lb)
screw)
2-18
TIGHTENING TORQUES
Thread
size
Fuel tank M6 6 7 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel sender M5 4 4 Nm (0.4 m·kg, 2.9 ft·lb)
Fuel cock M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Grab bar bolt M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
Front cowling nut M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Leg shield bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Reflector nut M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb)
Storage compartment and frame M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Seat nut M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Seat lock assembly bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front wheel axle M12 1 70 Nm (7.0 m·kg, 50 ft·lb)
Rear wheel nut M14 1 120 Nm (12.0 m·kg, 85 ft·lb)
Rear brake camshaft lever bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Rear brake pivot pin M10 1 32 Nm (3.2 m·kg, 23 ft·lb)
Front brake caliper bolt M10 2 35 Nm (3.5 m·kg, 25 ft·lb)
Front brake disc bolt M8 3 20 Nm (2.0 m·kg, 14 ft·lb) LT
Brake hose union bolt M10 2 30 Nm (3.0 m·kg, 22 ft·lb)

Front brake caliper bleed screw M7 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
Brake hose holder M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front fender M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Speedometer cable holder M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
TIP
Steering shaft and ring nut
1. Tighten the lower steering ring nut 38 Nm (3.8 m·kg, 27 ft·lb) with a torque wrench and the steering
nut wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower steering ring nut 12 Nm (1.2 m·kg, 8.7 ft·lb) with a torque wrench and the steering
nut wrench.
3. Install the rubber washer and the center steering ring nut.
4. Finger tighten the center steering ring nut, align the slots of both steering ring nuts, and then install
the lock washer.
5. Hold the lower and center steering ring nuts, and then tighten the upper steering ring nut 75 Nm (7.5
m·kg, 54 ft·lb) with a torque wrench and the steering nut wrench.
2-19
TIGHTENING TORQUES
4 5
3
2
1. Lower ring nut 4. Lock washer

2. Rubber washer 5. Upper ring nut
3. Center ring nut
TIP
Lower bracket and inner tube bolt/Front fork cap bolt
1. Tighten the lower bracket and inner tube bolt to 30 Nm (3.0 m·kg, 22 ft·lb).
2. Tighten the front fork cap bolt to 65 Nm (6.5 m·kg, 47 ft·lb).
3. Tighten the lower bracket and inner tube bolt to 65 Nm (6.5 m·kg, 47 ft·lb).
2-20
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360

EAS20370
ENGINE
Lubrication point Lubricant
Oil seal lips LS
Bearings E
O-rings LS
Cylinder head nut (thread part) E
Cylinder inner surface E
Crankshaft pin E
Connecting rod big end thrust surface E
Piston and piston rings E
Piston pin E
Connecting rod small end E
Timing chain E
Camshaft lobe surface M
Camshaft oil passage M
Rocker arm inner surface M
Rocker arm shaft M
Valve stems (intake and exhaust) M
Valve guides (intake and exhaust) M
Valve stem ends (intake and exhaust) E
Starter wheel gear M
Kickstarter pinion gear shaft M
Kickstarter pinion gear clip groove LS
Kickstarter shaft outer surface LS
Idle gear inner surface LS
Shell dolium grease

Secondary fixed sheave inner surface
RJ®
Shell dolium grease
Secondary sliding sheave inner surface
RJ®
Yamaha bond
Timing chain tensioner assembly bolt (front side) No.1215 (Three bond
No.1215®)
Yamaha bond
Crankcase mating surface No.1215 (Three bond
No.1215®)
2-21
EAS20380
CHASSIS
Lubrication point Lubricant
Engine bracket spacer LS
Steering bearing and oil seal LS
Throttle grip inner surface and throttle cables LS
Rear brake cable LS
Front wheel oil seal LS
Speedometer gear unit oil seal LS
Sidestand pivoting point and metal-to-metal moving parts LS
Centerstand shaft pivoting point and metal-to-metal moving parts LS
Brake caliper piston seal BF
Brake caliper piston dust seal S
Rubber parts inside the master cylinder BF
Front brake lever pivoting point and metal-to-metal moving parts S
Rear brake lever pivoting point and metal-to-metal moving parts LS
Caliper bracket slide pins and/or retaining bolts S
Rear brake pivot pin LS
Rear brake cam shaft LS
2-22
LUBRICATION SYSTEM DIAGRAMS
EAS2BK1003

EAS20410
LUBRICATION DIAGRAMS
2-23
1. Engine oil drain plug

2. Oil pump
3. Oil passage
4. Camshaft
5. Oil jet
6. Centrifugal filter
A. Areas filled with engine oil
B. Oil flow
C. To the oil pan
2-24
CABLE ROUTING
EAS20430
CABLE ROUTING
Handlebar (front view)
1 2
A
3
10
9 4
C
5
B 8 6
7
7
10
4
8 D
2-25
CABLE ROUTING
1. Turn signal relay

2. Meter assembly
3. Front left turn signal light lead
4. Brake cable
5. Speedometer cable
6. Throttle cable
7. Wire harness
8. Plastic band
9. Front right turn signal light lead
10. Brake hose
A. Route the brake cable through the cutout in the
guide on the handlebar.
B. Align the yellow tape on the wire harness with the
plastic band.
C. Route the wire strap of the wire harness over the
handlebar, and then hook it onto the right side of
the handlebar bracket.
D. Fasten the brake cable, throttle cable,
speedometer cable, brake hose, and wire harness
with a plastic band. Point the end of the plastic
band to the left, and then cut off the excess end of
the tie to 5–10 mm (0.20–0.39 in).
2-26
CABLE ROUTING
Front brake (right side view)
11 E 8
1 2
10 3 9
B
5 6
A 7
10 8
12 D
11
2-27
CABLE ROUTING
1. Main switch
2. Rectifier/regulator
3. Seat lock cable
4. Centerstand lock cable
5. Rectifier/regulator lead
6. Headlight lead
7. Auxiliary light lead
8. Brake hose
9. Brake hose holder
10. Wire harness
11. Plastic band
12. Battery lead
A. Route the main switch lead to the right of the front
storage compartment.
B. Make sure that the projection on the brake hose
grommet is pointing in the direction shown in the
illustration.
C. Route the seat lock cable through the frame from
the left hole in the frame. Fasten the seat lock
cable using the grommet on the cable.
D. Route the battery leads to the rear of the footrest
bracket and through the footboard.
E. Point the end of the plastic band inward.
2-28
CABLE ROUTING
Engine (right side view)
A 5
6 A
4
2 3 7 4
B C D
2-29
CABLE ROUTING
1. Fuel sender lead

2. Auto choke unit lead
3. AC magneto lead
4. Wire harness
5. Plastic band
6. Plastic locking tie
7. Starter motor lead
8. Starter relay
9. Engine bracket
A. Point the end of the plastic band or plastic locking
tie upward.
B. Face the white paint mark on the hose outward.
C. Fasten the cylinder head breather hose with the
holder.
D. Install the ground lead terminal and the ignition coil
using the same bolt.
E. Fasten the ignition coil lead with a plastic locking
tie. Point the end of the plastic locking tie forward.
F. Point the ends of the hose clamp downward.
G. After connecting the hose to the air induction
system filter, insert the end of the hose into the end
of the frame tube. (For air induction system
models)
2-30
CABLE ROUTING
Front fork (left side view)
A 8
7
3
6
9 B
5
4
2
2-31
CABLE ROUTING
1. Horn lead
2. Horn
4. Brake cable
5. Throttle cable
6. Speedometer cable
7. Brake hose
8. Wire harness
9. Plastic band
A. Connect the horn connectors so that the flat sides
of the connectors are facing forward.
B. Point the end of the plastic band to the right, and
then cut off the excess end of the tie to 5–10 mm
(0.20–0.39 in).
C. Route the brake cable over the cross tube of the
engine bracket.
D. Route the speedometer cable through the guide.
E. Route the speedometer cable through the left hole
in the inner fender.
2-32
CABLE ROUTING
Engine (left side view)
A B
D
2 3 C 4
6 E
1 F
10 H 9 8 G 7
2-33
CABLE ROUTING
1. Cylinder head breather hose

2. Ignition coil
3. Fuel cock vacuum hose
4. Fuel hose
5. Fuel tank overflow hose
6. Seat lock cable
7. Brake cable
8. Air filter case drain hose
9. Carburetor overflow hose
10. Throttle cable
A. Install the ignition coil connector so that the lead is
routed downward.
B. Make sure that the ignition coil lead is routed over
the spark plug lead.
C. Point the ends of the hose clamp rearward.
D. Install the fuel tank overflow hose completely onto
the hose fitting.
E. Route the seat lock cable to the inside of the
frame, and then route the cable to the inside of the
fuel tank overflow hose.
F. Fasten the fuel tank overflow hose with the two
holders on the license plate bracket.
G. After connecting the air filter case drain hose,
route the hose to the inside of the air duct.
H. Route the carburetor overflow hose between the
air shroud and the air duct and to the inside of the
centerstand bracket.
2-34
CABLE ROUTING
Battery and engine (top view)
18 A
P 17
1
2
O 16
3
15
B
N
4 C
M
D
L
5
K
6
J
14
7
8
F
I
9
10
13 11
12 G
2-35
CABLE ROUTING
1. Wire harness
2. Fuse box
3. Battery positive lead
4. Plastic band
5. Starter relay
6. Air induction system vacuum hose (For air
induction system models)
7. Starter motor
8. Starter motor lead
9. AC magneto lead
10. Auto choke unit lead
11. Fuel sender lead
12. Seat lock cable
13. Cylinder head breather hose
14. Fuel hose
15. Battery negative lead
16. Centerstand lock cable
17. Throttle cable
18. Brake cable
A. Route the wire harness, brake cable, and
centerstand lock cable under the frame cross
member.
B. After connecting the fuse box leads and negative
battery lead, route the leads through the hole in the
right side of the battery box.
C. Fasten the wire harness, positive battery lead, and
negative battery lead with a plastic band. Cut off
the excess end of the plastic band to 5–10 mm
(0.20–0.39 in).
D. Fasten the cylinder head breather hose with the
holder.
E. Fasten the air induction system vacuum hose with
the holder. (For air induction system models)
F. Route the AC magneto lead and auto choke unit
lead between the positive and negative starter
motor leads.
G. Route the seat lock cable to the inside of the seat
bracket and under the fuel sender lead.
H. Fasten the seat lock cable with the holder.
I. Down
J. Install the screw clamp so that the end of the
clamp screw is pointing to the left.
K. Route the throttle cables over the fuel cock
vacuum hose and fuel hose.
L. Apply grease (0.2 g) all around the grommet
(shaded area) on the centerstand lock cable, and
then insert the grommet into the pipe of the engine
bracket.
M. Route the throttle cables under the guide and
cross tube.
N. Route the centerstand lock cable and brake cable
to the outside of the footboard and battery box and
to the inside of the rib on the inner fender.
O. Route the centerstand lock cable to the right of the
brake cable.
P. Route the throttle cable to the left of the brake
cable.
2-36
CABLE ROUTING
2-37
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
ENGINE ...........................................................................................................3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
ADJUSTING THE ENGINE IDLING SPEED .............................................3-5
CHECKING THE EXHAUST GAS AT IDLE (Measuring the exhaust gas
at idle [when the air induction system is operation])
(For air induction system models) ............................................................ 3-6
ADJUSTING THE THROTTLE GRIP FREE PLAY ...................................3-7
CHECKING THE SPARK PLUG ............................................................... 3-7
CHECKING THE IGNITION TIMING.........................................................3-8 3
MEASURING THE COMPRESSION PRESSURE....................................3-9
CHECKING THE ENGINE OIL LEVEL....................................................3-10
CHANGING THE ENGINE OIL ...............................................................3-10
CHANGING THE TRANSMISSION OIL.................................................. 3-11
REPLACING THE AIR FILTER ELEMENT ............................................. 3-12
CLEANING THE V-BELT CASE AIR FILTER ELEMENT .......................3-12
REPLACING THE V-BELT ...................................................................... 3-14
CHECKING THE AIR FILTER CASE JOINT AND INTAKE
MANIFOLD ............................................................................................. 3-14
CHECKING THE FUEL LINE .................................................................. 3-14
CHECKING THE CRANKCASE BREATHER HOSE ..............................3-14
CHECKING THE EXHAUST SYSTEM....................................................3-15
CHASSIS ....................................................................................................... 3-16

ADJUSTING THE REAR DRUM BRAKE ................................................ 3-16
CHECKING THE BRAKE FLUID LEVEL................................................. 3-16
CHECKING THE FRONT BRAKE PADS ................................................ 3-16
CHECKING THE REAR BRAKE SHOES................................................ 3-17
CHECKING THE FRONT BRAKE HOSE................................................ 3-17
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-17
CHECKING AND LUBRICATE THE STEERING BEARINGS................. 3-18
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-18
CHECKING THE FRONT FORK ............................................................. 3-19
CHECKING THE TIRES..........................................................................3-19
CHECKING THE WHEELS ..................................................................... 3-21
CHECKING WHEEL BEARINGS ............................................................ 3-21
CHECKING AND LUBRICATING THE CABLES .................................... 3-21
LUBRICATING THE LEVERS .................................................................3-22
LUBRICATING THE SIDESTAND........................................................... 3-22
LUBRICATING THE CENTERSTAND ....................................................3-22
LUBRICATING THE REAR SUSPENSION............................................. 3-22
ELECTRICAL SYSTEM................................................................................. 3-23
CHECKING AND CHARGING THE BATTERY....................................... 3-23
CHECKING THE FUSES ........................................................................3-23
REPLACING THE HEADLIGHT BULB....................................................3-23
ADJUSTING THE HEADLIGHT BEAM ...................................................3-23
REPLACING THE AUXILIARY LIGHT BULB..........................................3-24
PERIODIC MAINTENANCE
EAS20450
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long-
er service life and reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EAUE0170
TIP
• From 18000 km (11000 mi), repeat the maintenance intervals starting from 3000 km (1900 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
EAUE0220
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE
JOB 1000 km 3000 km 6000 km 9000 km 12000 km 15000 km
(600 mi) (1900 mi) (3700 mi) (5600 mi) (7500 mi) (9300 mi)
1 * Fuel line • Check fuel and vacuum hoses √ √ √ √ √

for cracks or damage.
2 * Fuel cock filter • Check condition. √ √
• Check condition. √ √ √
• Clean and regap.
3 Spark plug
• Replace. √ √
4 * Valves • Check valve clearance. √ √ √ √ √

• Adjust.
5 * Carburetor • Adjust engine idling speed. √ √ √ √ √ √
Air induction sys- • Check the air cut-off valve,

reed valve, and hose for dam-
6 * tem (For air in- age. √ √ √ √ √
duction system
models) • Replace any damaged parts if
necessary.
EAUE0881
GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READING
CHECK OR MAINTENANCE
NO. ITEM JOB 1000 km 3000 km 6000 km 9000 km 12000 km 15000 km
(600 mi) (1900 mi) (3700 mi) (5600 mi) (7500 mi) (9300 mi)
1 Air filter element • Replace. √ √
V-belt case air fil-

2 • Clean. √ √ √ √ √
ter element
• Check operation, fluid level

and vehicle for fluid leakage. √ √ √ √ √ √
3 * Front brake
• Replace brake pads. Whenever worn to the limit
• Check operation and adjust

brake lever free play. √ √ √ √ √ √
4 * Rear brake
• Replace brake shoes. Whenever worn to the limit
3-1
ODOMETER READING
CHECK OR MAINTENANCE
NO. ITEM
JOB 1000 km 3000 km 6000 km 9000 km 12000 km 15000 km
(600 mi) (1900 mi) (3700 mi) (5600 mi) (7500 mi) (9300 mi)
• Check for cracks or damage.

• Check for correct routing and √ √ √ √ √
5 * Brake hose clamping.
• Replace. Every 4 years
6 * Brake fluid • Replace. Every 2 years
7 * Wheels • Check runout and for damage. √ √ √ √ √
• Check tread depth and for

damage.
8 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness

9 * Wheel bearings √ √ √ √ √
or damage.
• Check bearing play and steer-

ing for roughness. √ √ √ √ √ √
10 * Steering bearings
• Lubricate with lithium-soap- Every 12000 km (7500 mi)
based grease.
• Make sure that all nuts, bolts

11 * Chassis fasteners and screws are properly tight- √ √ √ √ √
ened.
Front brake lever

12 • Lubricate with silicone grease. √ √ √ √ √
pivot shaft
Rear brake lever • Lubricate with lithium-soap-

13 pivot shaft based grease. √ √ √ √ √
Sidestand, center- • Check operation.

14 • Lubricate with lithium-soap- √ √ √ √ √
stand based grease.
15 * Front fork • Check operation and for oil √ √ √ √ √

leakage.
Shock absorber • Check operation and shock

16 * √ √ √ √ √
assembly absorber for oil leakage.
• Change.
17 Engine oil • Check oil level and vehicle for √ Every 3000 km (1800 mi)
oil leakage.
Engine oil strain-

18 * er • Clean. √
19 Final transmis- • Check vehicle for oil leakage. √ √ √ √ √ √

sion oil • Change.
20 * V-belt • Replace. Every 18000 km (10500 mi)
21 * Front and rear • Check operation. √ √ √ √ √ √

brake switches
Moving parts and

22 • Lubricate. √ √ √ √ √
cables
• Check operation.
• Check throttle grip free play,
23 * Throttle grip and adjust if necessary. √ √ √ √ √
• Lubricate cable and grip hous-
ing.
Lights, signals • Check operation.

24 * and switches • Adjust headlight beam. √ √ √ √ √ √
3-2
EAU45610
TIP
• Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
• V-belt case air filter
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
• Replace the brake hose every four years and if cracked or damaged.
3-3
ENGINE
EAS20470
ENGINE
EAS20510
ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
• Seat/storage compartment
• Front cover
• Left and right side cover
Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
• Spark plug cap
• Spark plug
• Tappet covers ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Cylinder head breather assembly 4. Adjust:
• Air shroud • Valve clearance
3. Measure: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve clearance a. Loosen the locknut.
Out of specification → Adjust. b. Insert thickness gauge “1” between the ad-
justing screw and valve stem end.
Valve clearance (cold) c. Turn the adjusting screw “2” in direction “a” or
Intake
“b” until the specified valve clearance is ob-
0.08–0.12 mm (0.0032–0.0047 in)
Exhaust tained.
0.13–0.17 mm (0.0051–0.0067 in) Valve clearance gradually
Direction “a”
increases
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Valve clearance gradually
a. Turn the crankshaft clockwise. Direction “b”
decreases
b. When the piston is at TDC on the compres-
sion stroke, align the mark “a” on the cam-
shaft sprocket with the mark “b” on the Tappet adjusting tool
cylinder head. 90890-01311
c. Align mark “c” on the AC magneto rotor (with Six piece tappet set
the stationary pointer “d” on the right crank- YM-A5970
case).
d. Measure the valve clearance with a thickness
gauge.
Out of specification → Adjust.
3-4
ENGINE
d. Hold the adjusting screw to prevent it from 4. Check:

moving and tighten the locknut to specifica- • Engine idling speed
tion. Out of specification → Adjust.
Valve clearance adjusting screw Engine idling speed

locknut 1550–1750 r/min
T.
R.
6 Nm (0.6 m·kg, 4.3 ft·lb)

5. Adjust:
e. Measure the valve clearance again. • Engine idling speed
f. If the valve clearance is still out of specifica- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
tion, repeat above steps for adjusting the a. Turn the pilot screw “1” in until it is lightly seat-
valve clearance. ed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Turn the pilot screw “1” out the specified num-
5. Install: ber of turns.
• Air shroud Pilot screw turns out
• Cylinder head breather assembly 2 (For air induction system
• Tappet covers models)
• Spark plug 1–7/8 (Except for air induction
system models)
Cylinder head breather assembly
bolt
T.
R.
7 Nm (0.7 m·kg, 5.1 ft·lb)

Tappet cover
18 Nm (1.8 m·kg, 13 ft·lb) 1
Spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb)
6. Install:
• Left and right side cover
• Front cover
Refer to “GENERAL CHASSIS” on page 4-1. c. Turn the throttle stop screw “2” in direction “a”
or “b” until the specified engine idling speed is
EAS2BK1004
obtained.
ADJUSTING THE ENGINE IDLING SPEED
TIP Direction “a”
Prior to checking the engine idling speed, the air Engine idling speed is increased.
filter element should be clean, and the engine Direction “b”
should have adequate compression. Engine idling speed is decreased.
1. Start the engine and let it warm up for several

minutes.
b a
2. Remove:
• Front cover 2
• Left side cover
3. Install:
• Digital tachometer
(To the spark plug lead of cylinder)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Digital tachometer
90890-06760 6. Adjust:
YU-39951-B • Throttle grip free play
Refer to “ADJUSTING THE THROTTLE
GRIP FREE PLAY” on page 3-7.
3-5
ENGINE
TIP
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in) Prior to checking the engine idling speed, the air
filter element should be clean, and the engine
7. Install: should have adequate compression.
• Left side cover
• Front cover Engine idling speed
• Seat/storage compartment 1550–1750 r/min
6. Stop air induction system operation.
EAS2BK2001
CHECKING THE EXHAUST GAS AT IDLE TIP

(Measuring the exhaust gas at idle [when the Use a clip to pinch the hose “1” running from the
air induction system is operation]) (For air cylinder head to the reed valve assembly to pre-
induction system models) vent the air induction system from operating.
1. Stand the vehicle on a level surface. Make sure not to damage the hose while crimp-
TIP ing it.
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright. 1
2. Remove:
• Front cover
3. Install:
• Pocket tester “1”
(onto the engine oil drain bolt)
7. Install:
(onto the spark plug lead of cylinder)
• Digital tachometer “1”
Pocket tester • Carbon monoxide and hydrocarbon tester “2”
90890-03132 • Sampling probe “3”
Digital tachometer TIP
90890-06760 • Since it is necessary to insert the sampling
YU-39951-B probe 600 mm (23.6 in) into the tail pipe, be
sure to use a heat-resistant rubber tube as
shown in the illustration.
• Be sure to set the heat-resistant rubber tube so
that exhaust gas does not leak out.
• Before using the carbon monoxide and hydro-
carbon tester, be sure to read the user’s man-
ual.
1
1
4. Start the engine and warm it up until the spec-
ified oil temperature is reached.
Oil temperature
70.0–80.0 °C (158.00–176.00 °F)
5. Check:
• Engine idling speed
3-6
ENGINE

2 3.0–5.0 mm (0.12–0.20 in)
2. Adjust:
• Throttle grip free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjusting nut “2” in direction “a” or “b”
3 until the specified throttle grip free play is ob-
tained.
8. Measure:
• CO density Direction “a”
Throttle grip free play is increased.
CO% (air induction system OFF) Direction “b”
2.0–8.0 % Throttle grip free play is decreased.
9. Remove the clip that is pinching the hose so c. Tighten the locknut.
that the air induction system operates.
10.Measure:
• CO density
CO% (air induction system ON)

0.0–3.0 %
Out of specification → Check air induction

system.
Refer to “AIR INDUCTION SYSTEM (FOR
AIR INDUCTION SYSTEM MODELS)” on EWA2BK1010
page 6-11. WARNING
11.Install:
After adjusting the throttle grip free play,
• Front cover
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
EAS2BK1006 change.
ADJUSTING THE THROTTLE GRIP FREE
PLAY ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS20690
TIP
CHECKING THE SPARK PLUG
Prior to adjusting the throttle grip free play, the 1. Remove:
engine idling speed should be adjusted properly. • Front cover
1. Check: Refer to “GENERAL CHASSIS” on page 4-1.
• Throttle grip free play “a” • Spark plug cap
Out of specification → Adjust. 2. Remove:
• Spark plug
ECA13330
NOTICE
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
a with compressed air to prevent it from falling
into the cylinder.
3. Check:
• Spark plug type
Incorrect → Change.
3-7
ENGINE
EAS20700
Manufacturer/model CHECKING THE IGNITION TIMING

NGK/CR7E TIP
Prior to checking the ignition timing, check the
4. Check: wiring connections of the entire ignition system.
• Electrode “1” Make sure all connections are tight and free of
Damage/wear → Replace the spark plug. corrosion.
• Insulator “2”
Abnormal color → Replace the spark plug. 1. Remove:
Normal color is medium-to-light tan. • Front cover
2. Remove:
• Timing plug
3. Connect:
• Timing light
(onto the spark plug lead)
Timing light
90890-03141
YU-03141
5. Clean: Digital tachometer
• Spark plug 90890-06760
(with a spark plug cleaner or wire brush) YU-39951-B
6. Measure:
4. Check:
• Spark plug gap “a”
• Ignition timing
Out of specification → Regap.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine, warm it up for several min-
Spark plug gap
utes, and then let it run at the specified en-
0.7–0.8 mm (0.028–0.031 in)
gine idling speed.
Engine idling speed

1550–1750 r/min
b. Check that the stationary pointer “a” is within

the firing range of mark “b” on the AC magne-
to rotor.
Incorrect firing range → Check the ignition
system.
TIP
The ignition timing is not adjustable.
7. Install:
• Spark plug
Spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb)
T.
R.
TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
8. Install:
• Spark plug cap
• Front cover ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-8
ENGINE
5. Install: 6. Measure:
• Timing plug • Compression pressure
6. Install: Out of specification → Refer to steps (c) and
• Front cover (d).
Standard compression pressure
EAS20710
(at sea level)
MEASURING THE COMPRESSION 1200 kPa/600 r/min (12.0
PRESSURE kgf/cm²/600 r/min, 170.6 psi/600
TIP r/min)
• Insufficient compression pressure will result in Minimum–maximum
a loss of performance. 1040–1340 kPa (10.4–13.4
• Before measuring compression pressure, kgf/cm², 147.9–190.5 psi)
valve clearance is proper. Refer to “ADJUST-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ING THE VALVE CLEARANCE” on page 3-4. a. Turn the main switch to “ON”.
1. Remove: b. With the throttle wide open, crank the engine
• Front cover until the reading on the compression gauge
Refer to “GENERAL CHASSIS” on page 4-1. stabilizes.
EWA2BK1001
2. Start the engine, warm it up for several min- WARNING
utes, and then turn it off.
3. Disconnect: To prevent sparking, ground the spark plug
• Spark plug cap lead before cranking the engine.
4. Remove: c. If the compression pressure is above the
• Spark plug maximum specification, check the cylinder
ECA2BK1003
head, valve surfaces and piston crown for
NOTICE carbon deposits.
Before removing the spark plug, use com- Carbon deposits → Eliminate.
pressed air to blow away any dirt accumulat- d. If the compression pressure is below the min-
ed in the spark plug wells to prevent it from imum specification, pour a teaspoonful of en-
falling into the cylinder. gine oil into the spark plug bore and measure
5. Install: again.
• Compression gauge “1” Refer to the following table.
Compression pressure (with oil applied into
Compression gauge the cylinder)
90890-03081
Engine compression tester Reading Diagnosis
YU-33223 Higher than without Piston ring(s) wear or
Compression gauge extension S oil damage → Repair.
90890-03195 Piston, valves, cylin-
der head gasket or
Same as without oil
1 piston possibly defec-
tive → Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
• Spark plug
Spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb)
T.
R.
8. Connect:
• Spark plug cap
3-9
ENGINE
9. Install: ECA2BK1005
• Front cover NOTICE

Refer to “GENERAL CHASSIS” on page 4-1. • Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
EAS20730
clutch slippage. Therefore, do not add any
CHECKING THE ENGINE OIL LEVEL
chemical additives or use engine oils with a
1. Stand the vehicle on a level surface.
grade of CD or higher and do not use oils la-
TIP
beled “ENERGY CONSERVING II”.
• Place the vehicle on the centerstand. • Do not allow foreign materials to enter the
• Make sure the vehicle is upright. crankcase.
2. Start the engine, warm it up for several min- 4. Start the engine, warm it up for several min-
utes, and then turn it off. utes, and then turn it off.
3. Check: 5. Check the engine oil level again.
• Engine oil level TIP
Remove the dipstick “1” the engine oil level
Before checking the engine oil level, wait a few
should be between the minimum level mark
minutes until the oil has settled.
“a” and maximum level mark “b”.
Below the minimum level mark → Add the
EAS20810
recommended engine oil to the proper level. CHANGING THE ENGINE OIL
TIP 1. Start the engine, warm it up for several min-
Before checking the engine oil level, wait a few utes, and then turn it off.
minutes until the oil has settled. 2. Place a container under the engine oil drain
bolt.
3. Remove:
1 • Dipstick “1”
• Engine oil drain bolt “2”
(along with the gasket)
1
b
a
Recommended brand
YAMALUBE
Type
SAE 20W-40 or 10W-30
Recommended engine oil grade
API service SE type or higher, 2
JASO standard MA
-20 -10 0 10 20 30 40 50 ˚C
SAE 10W-30
SAE 10W-40
2
SAE 10W-50
SAE 15W-40
4. Drain:
SAE 20W-40 • Engine oil
SAE 20W-50 (completely from the crankcase)
3-10
ENGINE
5. If the oil strainer is also to be cleaned, per- Refer to “GENERAL CHASSIS” on page 4-1.
form the following procedure. b. Slightly loosen the engine oil check bolt “1”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the engine oil drain plug “1” and oil 1
strainer “2”.
b. Install a new O-ring “3”.
c. Start the engine and keep it idling until engine

oil starts to seep from the engine oil check
bolt hole. If no engine oil comes out after one
minute, turn the engine off so that it will not
c. Install the engine oil drain plug. seize.
d. Check the engine oil passages, the oil strain-
Engine oil drain plug er and the oil pump for damage or leakage.
31 Nm (3.1 m·kg, 22 ft·lb) Refer to “OIL PUMP” on page 5-50.
T.
R.
e. Start the engine after solving the problem(s)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
and check the engine oil pressure again.
6. Install: f. Tighten the engine oil check bolt to specifica-
• Engine oil drain bolt tion.
(along with a new gasket)
Engine oil check bolt
Engine oil drain bolt For air induction system models
T.
20 Nm (2.0 m·kg, 14 ft·lb)

R.
7 Nm (0.7 m·kg, 5.1 ft·lb)

T.
R.
Except for air induction system

7. Fill: models
• Engine oil 20 Nm (2.0 m·kg, 14 ft·lb)
(with the specified amount of the recom-
mended engine oil) g. Install the front cover.
Engine oil quantity ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Periodic oil change
EAS20830
1.00 L (1.06 US qt, 0.88 Imp.qt)
CHANGING THE TRANSMISSION OIL
Quantity (disassembled)
1.20 L (1.27 US qt, 1.06 Imp.qt) 1. Stand the vehicle on a level surface.
TIP
8. Install: • Place the vehicle on the centerstand.
• Dipstick • Make sure the vehicle is upright.
9. Start the engine, warm it up for several min-
2. Start the engine, warm it up for several min-
10.Check:
3. Place a container under the transmission.
• Engine
4. Remove:
(for engine oil leaks)
• Oil filler cap
11.Check:
• Transmission oil drain bolt “1”
• Engine oil level
(along with the gasket)
Refer to “CHECKING THE ENGINE OIL
Completely drain the transmission oil.
LEVEL” on page 3-10.
12.Check:
• Engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Removing the front cover.
3-11
ENGINE
1 1
5. Install:
• Transmission oil drain bolt
(along with a new gasket)
Transmission oil drain bolt

23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
6. Fill:
• Transmission oil 2
mended transmission oil)
2. Check:
Type • Air filter element
SAE 85W-140 (GL5) Damage → Replace.
Periodic oil change TIP
0.13 L (0.14 US qt, 0.11 Imp.qt)
• Replace the air filter element every 6000 km of
Quantity (disassembled)
0.15 L (0.16 US qt, 0.13 Imp.qt) operation.
• The air filter needs more frequent service if you
7. Install: are riding in unusually wet or dusty areas.
• Oil filler cap “1” • Do not clean by blowing the compression air.
• O-ring “2” New 3. Install:
• Air filter element
• Air filter case cover
ECA2BK1006
NOTICE
1 Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
2 New air filter element will also affect carburetor
synchronization, leading to poor engine per-
8. Start the engine, warm it up for several min- formance and possible overheating.
utes, and then turn it off. TIP
9. Check:
When installing the air filter element into the air
• Transmission oil leakage
filter case cover, make sure that the sealing sur-
EAS20960 faces are aligned to prevent any air leaks.
REPLACING THE AIR FILTER ELEMENT
1. Remove: EAS2BK1007
• Air filter case cover “1” CLEANING THE V-BELT CASE AIR FILTER
• Air filter element “2” ELEMENT
1. Remove:
• V-belt case air duct “1”
3-12
ENGINE
1
2. Remove: TIP
• V-belt case air filter element guide “1” After rinsing, wipe off any excessive solvent on
1 the V-belt case air filter element.
ECA2BK1009
NOTICE
Do not wring the V-belt chamber air filter ele-
ment.
6. Apply recommended oil on all surfaces of the
V-belt case, and then squeeze off any exces-
sive oil. V-belt chamber filter element should
be kept moist, but not dripping.
3. Remove:
• V-belt case air filter element “1” Recommended oil
Yamaha foam air filter oil or oth-
er quality foam air filter oil
4. Check:
• V-belt case air filter element
Damaged → Replace.
7. Install:
5. Rinse:
• V-belt case air filter element “1”
• V-belt case air filter element “1”
(with solvent)
EWA2BK1002
WARNING
Do not use solvent with a flash point (e.g. fu-
el) to rinse the V-belt chamber air filter ele-
1
ment. Such solvent may lead to ignition or
explosion.
8. Install:
• V-belt case air filter element guide “1”
3-13
ENGINE
V-belt case air filter element 1

guide screw 2
T.
R.
6 Nm (0.6 m·kg, 4.3 ft·lb)
3. Install:
• Seat
• Storage compartment
9. Install: EAS21030
• V-belt case air duct “1” CHECKING THE FUEL LINE

1. Remove:
V-belt case air duct screw • Seat
6 Nm (0.6 m·kg, 4.3 ft·lb) • Storage compartment
T.
R.
• Left side cover

2. Check:
• Fuel hose “1”
• Fuel cock vacuum hose “2”
Cracks/tears → Replace.
Loose connections → Connect properly.
ECA14940
NOTICE
1 Make sure the fuel tank breather hose is rout-
ed correctly.
EAS2BK1008
REPLACING THE V-BELT

Refer to “V-BELT AUTOMATIC TRANSMIS- 1
SION” on page 5-34. 2
EAS2BK1009
CHECKING THE AIR FILTER CASE JOINT

AND INTAKE MANIFOLD
1. Remove:
• Seat
Refer to “GENERAL CHASSIS” on page 4-1. 3. Install:
2. Check: • Left side cover
• Air filter case joint “1” • Storage compartment
• Intake manifold “2” • Seat
Cracks/tears → Replace. Refer to “GENERAL CHASSIS” on page 4-1.
EAS21070
CHECKING THE CRANKCASE BREATHER

HOSE
1. Remove:
• Seat
3-14
ENGINE
• Front cover
Refer to “GENERAL CHASSIS” on page 4-1. 2
2. Check: 1
• Crankcase breather hose “1” 1
• Transmission breather hose “2”
ECA13450
NOTICE
Make sure the crankcase breather hose is 3
routed correctly.
3. Install:
• Front cover
• Seat
EAS21080
CHECKING THE EXHAUST SYSTEM

1. Check:
• Muffler “1”
Cracks/damage → Replace.
• Gasket
Exhaust gas leaks → Replace.
2. Check:
Tightening torque
• Exhaust pipe nut “2”
• Muffler bolt “3”
Exhaust pipe nut

13 Nm (1.3 m·kg, 9.4 ft·lb)
T.
R.
Muffler bolt
31 Nm (3.1 m·kg, 22 ft·lb)
3-15
CHASSIS
EAS21140
• Make sure the vehicle is upright.
CHASSIS • In order to ensure a correct reading of the
EAS2BK1016
brake fluid level, make sure the top of the brake
ADJUSTING THE REAR DRUM BRAKE fluid reservoir is horizontal.
1. Check: 2. Check:
• Brake lever free play “a” • Brake fluid level
Out of specification → Adjust. Below the minimum level mark “a” → Add the
recommended brake fluid to the proper level.
Rear brake lever free play
10.0–20.0 mm (0.39–0.79 in) Specified brake fluid
DOT 3 or 4
2. Adjust:
• Brake lever free play EWA13090
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING
a. Turn the adjusting nut “1” in direction “a” or “b”
• Use only the designated brake fluid. Other
until the specified brake lever free play is ob-
brake fluids may cause the rubber seals to
tained.
deteriorate, causing leakage and poor
Direction “a” brake performance.
Brake lever free play is increased. • Refill with the same type of brake fluid that
Direction “b” is already in the system. Mixing brake fluids
Brake lever free play is decreased. may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540
NOTICE
b Brake fluid may damage painted surfaces
a
1 and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
ECA2BK1007
EAS21250
NOTICE CHECKING THE FRONT BRAKE PADS
After adjusting the brake lever free play, The following procedure applies to all of the
make sure there is no brake drag. brake pads.
1. Operate the brake.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
EAS21240
• Front brake pads
CHECKING THE BRAKE FLUID LEVEL
Wear indicator grooves “a” almost disap-
peared → Replace the brake pads as a set.
TIP Refer to “FRONT BRAKE” on page 4-14.
• Place the vehicle on the centerstand.
3-16
CHASSIS
EAS21350
BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWA13100
WARNING
a
a Bleed the hydraulic brake system whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• brake operation is faulty.
EAS2BK1011
CHECKING THE REAR BRAKE SHOES TIP

1. Operate the brake. • Be careful not to spill any brake fluid or allow
2. Check: the brake master cylinder reservoir to overflow.
• Wear indicator “1” • When bleeding the hydraulic brake system,
Reaches the wear limit line “2” → Replace the make sure there is always enough brake fluid
brake shoes as a set. before applying the brake. Ignoring this pre-
Refer to “REAR BRAKE” on page 4-27. caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be necessary to let
1 the brake fluid settle for a few hours.
• Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
2
1. Bleed:
• Hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake fluid reservoir to the proper level
EAS21280
with the recommended brake fluid.
CHECKING THE FRONT BRAKE HOSE
b. Install the diaphragm (brake master cylinder
1. Check:
reservoir or brake fluid reservoir).
• Brake hose “1”
c. Connect a clear plastic hose “1” tightly to the
Cracks/damage/wear → Replace.
bleed screw “2”.
2. Check:
d. Place the other end of the hose into a con-
• Brake hose holder
tainer.
Loose → Tighten the holder bolt.
e. Slowly apply the brake several times.
3. Hold the vehicle upright and apply the front
f. Fully pull the brake lever and hold it in posi-
brake several times.
tion.
4. Check:
g. Loosen the bleed screw.
• Brake hose
Brake fluid leakage → Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-14.
3-17
CHASSIS
TIP
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the
throttle grip.
h. Tighten the bleed screw and then release the
brake lever.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the brake fluid in
the plastic hose.
j. Tighten the bleed screw to specification. 3. Remove:
• Front upper cowling
Front brake caliper bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
4. Adjust:
R.
k. Fill the brake fluid reservoir to the proper level • Steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
with the recommended brake fluid.
a. Remove the upper ring nut “1”, the lock wash-
EWA13110
er “2”, the center ring nut “3” and the rubber
WARNING washer “4”.
b. Loosen the lower ring nut “5” and then tighten
After bleeding the hydraulic brake system,
it to specification with a steering nut wrench
check the brake operation.
“6”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ TIP
EAS2BK1012
Set the torque wrench at a right angle to the
CHECKING AND LUBRICATE THE steering nut wrench.
STEERING BEARINGS
Refer to “STEERING HEAD” on page 4-41.
EAS21520
CHECKING AND ADJUSTING THE

STEERING HEAD
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on the centerstand so that the
front wheel is elevated.
2. Check:
• Steering head 6
Grasp the bottom of the front fork legs and 5
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
Steering nut wrench

90890-01403
YU-A9472
3-18
CHASSIS
Lower ring nut (initial tightening Ring nut wrench

torque) 90890-01268
T.
R.
38 Nm (3.8 m·kg, 27 ft·lb) Spanner wrench

YU-01268
c. Loosen the lower ring nut “5” completely, Steering nut wrench
then tighten it to specification. 90890-01403
Lower ring nut (final tightening YU-A9472
torque)
T.
R.
12 Nm (1.2 m·kg, 8.7 ft·lb)

Upper ring nut
EWA13140 75 Nm (7.5 m·kg, 54 ft·lb)
T.
R.
WARNING
Do not overtighten the lower ring nut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Grasp the bottom of the front fork legs and 5. Install:

gently rock the front fork. If any binding is felt, • Front upper cowling
remove the lower bracket and check the up- Refer to “GENERAL CHASSIS” on page 4-1.
per and lower bearings. EAS21530
Refer to “STEERING HEAD” on page 4-41. CHECKING THE FRONT FORK

e. Install the rubber washer. 1. Stand the vehicle on a level surface.
EWA13120
f. Install the center ring nut.
WARNING
g. Finger tighten the center ring nut, then align
the slots of both ring nuts. If necessary, hold Securely support the vehicle so that there is
the lower ring nut and tighten the upper ring no danger of it falling over.
nut until their slots are aligned. 2. Check:
TIP • Inner tube
Once the slots are aligned, turn the center ring Damage/scratches → Replace.
nut until both slots point to the tightening direc- • Oil seal
tion. Oil leakage → Replace.
3. Hold the vehicle upright and apply the front
h. Install the lock washer “2”.
brake.
TIP 4. Check:
Make sure the lock washer tabs “a” sit correctly • Front fork operation
in the ring nut slots “b”. Push down hard on the handlebar several
times and check if the front fork rebounds
2 smoothly.
Rough movement → Repair.
a Refer to “FRONT FORK” on page 4-34.
i. Hold the lower and center ring nuts with a ring

nut wrench and tighten the upper ring nut with
a steering nut wrench.
EAS21660
CHECKING THE TIRES

The following procedure applies to both of the
tires.
3-19
CHASSIS
1. Check:
• Tire pressure
1. Tire tread depth

2. Sidewall
3. Wear indicator
EWA13180
WARNING
Wear limit (front)
• The tire pressure should only be checked 1.0 mm (0.04 in)
and regulated when the tire temperature Wear limit (rear)
equals the ambient air temperature. 1.0 mm (0.04 in)
• The tire pressure and the suspension must
EWA14080
be adjusted according to the total weight
WARNING
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding • Do not use a tubeless tire on a wheel de-
speed. signed only for tube tires to avoid tire fail-
• Operation of an overloaded vehicle could ure and personal injury from sudden
cause tire damage, an accident or an injury. deflation.
NEVER OVERLOAD THE VEHICLE. • When using a tube tire, be sure to install the
correct tube.
• Always replace a new tube tire and a new
Tire air pressure (measured on
cold tires) tube as a set.
Loading condition • To avoid pinching the tube, make sure the
0–83 kg (0–183 lb) wheel rim band and tube are centered in the
Front wheel groove.
175 kPa (1.75 kgf/cm², 25 psi) • Patching a punctured tube is not recom-
Rear mended. If it is absolutely necessary to do
250 kPa (2.50 kgf/cm², 36 psi) so, use great care and replace the tube as
Loading condition soon as possible with a good quality re-
83–153 kg (183–337 lb) placement.
Front
175 kPa (1.75 kgf/cm², 25 psi)
Rear
250 kPa (2.50 kgf/cm², 36 psi)
Maximum load
153 kg (337 lb)
* Total weight of rider, passenger, cargo
and accessories
EWA13190
WARNING
It is dangerous to ride with a worn-out tire. A. Tire
When the tire tread reaches the wear limit, re- B. Wheel
place the tire immediately.
2. Check: Tube wheel Tube tire only
• Tire surfaces Tubeless wheel Tube or tubeless tire
Damage/wear → Replace the tire.
3-20
CHASSIS
EWA14090
WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one
approved by Yamaha is used on this vehicle.
EAS21670
Front tire CHECKING THE WHEELS

Size 1. Check:
3.50–10 51J (For air induction • Wheel
system models) Damage/out-of-round → Replace.
100/90–10 56J (Except for air in- EWA13260
duction system models) WARNING

Manufacturer/model Never attempt to make any repairs to the
CHENG SHIN/S922S (For air in-
wheel.
CHENG SHIN/C922 (Except for TIP
air induction system models) After a tire or wheel has been changed or re-
placed, always balance the wheel.
Rear tire
Size EAS2BK1013
3.50–10 51J (For air induction CHECKING WHEEL BEARINGS

system models) Refer to “FRONT WHEEL” on page 4-6.
100/90–10 56J (Except for air in- EAS21690
duction system models) CHECKING AND LUBRICATING THE
Manufacturer/model CABLES
CHENG SHIN/S6007 (For air in- EWA13270
duction system models) WARNING

CHENG SHIN/C940 (Except for
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
EWA2BK1003 place damaged outer cable and inner cables
WARNING as soon as possible.
New tires have a relatively low grip on the 1. Check:
road surface until they have been slightly • Outer cable
worn. Therefore, approximately 100 km Damage → Replace.
should be traveled at normal speed before 2. Check:
any high-speed riding is done. • Cable operation
TIP Rough movement → Lubricate.
• For tires with a direction of rotation mark “1”: Recommended lubricant
• Install the tire with the mark pointing in the di- Engine oil or a suitable cable lu-
rection of wheel rotation. bricant
• Align the mark “2” with the valve installation
point. TIP
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
3-21
CHASSIS
EAS21700
LUBRICATING THE LEVERS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
Recommended lubricant
Front brake lever
Silicone grease
Rear brake lever
Lithium-soap-based grease
EAS21720
LUBRICATING THE SIDESTAND

moving parts of the sidestand.
EAS21730
LUBRICATING THE CENTERSTAND

moving parts of the centerstand.
EAS2BK1014
LUBRICATING THE REAR SUSPENSION

moving parts of the rear suspension.
3-22
ELECTRICAL SYSTEM
EAS21750 ECA13690
ELECTRICAL SYSTEM NOTICE

Avoid touching the glass part of the head-
EAS21760
CHECKING AND CHARGING THE BATTERY light bulb to keep it free from oil, otherwise
Refer to “ELECTRICAL COMPONENTS” on the transparency of the glass, the life of the
page 7-31. bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
EAS21770
thoroughly clean it with a cloth moistened
CHECKING THE FUSES with alcohol or lacquer thinner.
Refer to “ELECTRICAL COMPONENTS” on
page 7-31. 7. Hook:
• Headlight bulb holder
EAS21790
8. Install:
REPLACING THE HEADLIGHT BULB
• Head light bulb cover
1. Remove:
9. Connect:
• Headlight coupler
10.Install:
2. Disconnect:
• Headlight coupler “1”
3. Remove:
• Headlight bulb cover “2” EAS21810
ADJUSTING THE HEADLIGHT BEAM

1. Remove:
2 Refer to “GENERAL CHASSIS” on page 4-1.
1 2. Adjust:
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or
“b”.
Direction “a”
4. Unhook: Headlight beam is raised.
• Headlight bulb holder “1” Direction “b”
5. Remove: Headlight beam is lowered.
• Headlight bulb “2”
1
b a
2
1
EWA13320
WARNING ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Since the headlight bulb gets extremely hot, 3. Install:

keep flammable products and your hands • Front upper cowling
away from the bulb until it has cooled down. Refer to “GENERAL CHASSIS” on page 4-1.
6. Install:
• Headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
3-23
ELECTRICAL SYSTEM
EAS2BK1015
REPLACING THE AUXILIARY LIGHT BULB

1. Remove:
2. Remove:
• Auxiliary light bulb socket “1”
• Auxiliary light bulb
3. Install:
• Auxiliary light bulb New
• Auxiliary light bulb socket
4. Install:
3-24
ELECTRICAL SYSTEM
3-25
CHASSIS
GENERAL CHASSIS.......................................................................................4-1
FRONT WHEEL............................................................................................... 4-6

REMOVING THE FRONT WHEEL............................................................ 4-8
CHECKING THE FRONT WHEEL ............................................................ 4-8
ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................... 4-9
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC).................. 4-10
REAR WHEEL ...............................................................................................4-12

REMOVING THE REAR WHEEL (DRUM).............................................. 4-13
CHECKING THE REAR WHEEL............................................................. 4-13
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-13
INSTALLING THE REAR WHEEL (DRUM) ............................................4-13
FRONT BRAKE ............................................................................................. 4-14

INTRODUCTION .....................................................................................4-19
CHECKING THE FRONT BRAKE DISC ................................................. 4-19
REPLACING THE FRONT BRAKE PADS .............................................. 4-20
REMOVING THE FRONT BRAKE CALIPER..........................................4-21
DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-21
4
CHECKING THE FRONT BRAKE CALIPER ..........................................4-22
ASSEMBLING THE FRONT BRAKE CALIPER ...................................... 4-22
INSTALLING THE FRONT BRAKE CALIPER ........................................ 4-22
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-23
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-24
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-24
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-25
REAR BRAKE ...............................................................................................4-27

REMOVING THE REAR BRAKE............................................................. 4-28
CHECKING THE REAR BRAKE SHOES................................................ 4-28
ASSEMBLING THE REAR BRAKE SHOE PLATE .................................4-29
HANDLEBAR ................................................................................................4-31
REMOVING THE HANDLEBAR..............................................................4-32
CHECKING THE HANDLEBAR ..............................................................4-32
INSTALLING THE HANDLEBAR ............................................................ 4-32
FRONT FORK................................................................................................4-34
REMOVING THE FRONT FORK LEGS.................................................. 4-36
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-36
CHECKING THE FRONT FORK LEGS .................................................. 4-37
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-37
INSTALLING THE FRONT FORK LEGS ................................................ 4-39
STEERING HEAD.......................................................................................... 4-41
REMOVING THE LOWER BRACKET.....................................................4-43
CHECKING THE STEERING HEAD .......................................................4-43
INSTALLING THE LOWER BRACKET ...................................................4-44
REAR SHOCK ABSORBER ASSEMBLY ....................................................4-45

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-46
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-46
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-46
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the seat and side covers
23 Nm (2.3 m • kg, 17 ft • Ib)
T.R
1
.
7
8 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
3
2
9
4 5
Order Job/Part Q’ty Remarks

1 Seat 1
2 Tool kits 1
3 Storage compartment 1
4 Front cover 1
5 Tail/brake light coupler 1 Disconnect.
6 Tail/brake light assembly 1
7 Grab bar 1
8 Right side cover 1
9 Left side cover 1
For installation, reverse the removal proce-
dure.
4-1
GENERAL CHASSIS
Removing the footboard
4 1
3
5
8 2
9

Refer to “GENERAL CHASSIS” on page
Storage compartment 4-1.
Left side cover/Right side cover 4-1.
1 Footboard mat 1
2 Left footboard side cover 1
3 Right footboard side cover 1
4 Battery cover 1
5 Negative battery lead 1 Disconnect.
6 Positive battery lead 1 Disconnect.
7 Battery 1
8 Fuse box 1
9 Footboard 1
dure.
4-2
GENERAL CHASSIS
Removing the front cowling and leg shield

2 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7
T.R
.
4 6
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.R
.

Footboard 4-1.
1 Front upper cowling 1
2 Headlight coupler 1 Disconnect.
3 Auxiliary light coupler 1 Disconnect.
4 Headlight assembly 1
5 Front cowling 1
6 Main switch cover 1
7 Front storage compartment cover 1
8 Leg shield 1
dure.
4-3
GENERAL CHASSIS
Removing the handlebar cover
13
2
7 8
9
6
12 10
11
3 5

1 Left rearview mirror 1
2 Right rearview mirror 1
3 Front handlebar cover 1
4 Left turn signal light coupler 1 Disconnect.
5 Right turn signal light coupler 1 Disconnect.
6 Turn signal light assembly 1
7 Starter switch coupler 1 Disconnect.
8 Speedometer coupler 1 Disconnect.
9 Speedometer connector 1 Disconnect.
10 Left handlebar switch coupler 2 Disconnect.
11 Speedometer cable 1 Disconnect.
12 Turn signal relay coupler 1 Disconnect.
13 Rear handlebar cover 1
dure.
4-4
GENERAL CHASSIS
Removing the air filter case
2 4
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.R
.

Storage compartment 4-1.
1 Crankcase breather hose 1 Disconnect.
2 Air filter case joint clamp screw 1 Loosen.
3 Air filter case 1
4 Air filter case cover 1
5 Air filter 1
dure.
4-5
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake disc
70 Nm (7.0 m • kg, 50 ft • lb) 35 Nm (3.5 m • kg, 25 ft • Ib)
T.R
T.R
.
.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.R
.
4 Nm (0.4 m • kg, 2.9 ft • Ib)

T.R
.

Place the vehicle on a suitable stand so that
the front wheel is elevated.
1 Speedometer cable 1 Disconnect.
2 Front brake caliper 1
3 Front wheel axle self-locking nut 1
4 Front wheel axle 1
5 Front wheel assembly 1
6 Spacer 1
7 Speedometer gear unit 1
8 Brake disc 1
dure.
4-6
FRONT WHEEL
Disassembling the front wheel

1 Bearing 1
2 Collar 1
3 Oil seal 1
4 Bearing 1
For assembly, reverse the disassembly pro-
cedure.
4-7
FRONT WHEEL
EAS21900
REMOVING THE FRONT WHEEL Radial wheel runout limit

1. Stand the vehicle on a level surface. 1.0 mm (0.04 in)
EWA13120
Lateral wheel runout limit
WARNING 1.0 mm (0.04 in)
2. Remove:
• Brake caliper
TIP
Do not apply the brake lever when removing the
brake caliper.
3. Elevate:
• Front wheel
TIP
Place the vehicle on a suitable stand so that the 4. Check:
front wheel is elevated. • Wheel bearings
Front wheel turns roughly or is loose → Re-
4. Remove:
place the wheel bearings.
• Front wheel axle • Oil seal
EAS21920 Damage/wear → Replace.
CHECKING THE FRONT WHEEL
1. Check:
• Wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
5. Replace:
• Wheel bearings New
• Oil seal New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWA13460 a. Clean the outside of the front wheel hub.
WARNING b. Remove the oil seal “1” with a flathead screw-
Do not attempt to straighten a bent wheel ax- driver.
le. TIP
To prevent damaging the wheel, place a rag “2”
2. Check:
between the screwdriver and the wheel surface.
• Tire
• Front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-19 and “CHECKING THE WHEELS” on
page 3-21.
3. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limits → Replace.
4-8
FRONT WHEEL
c. Remove the wheel bearings “3” with a gener- b. When the front wheel stops, put an “X1” mark
al bearing puller. at the bottom of the wheel.
d. Install the new wheel bearings and oil seal in c. Turn the front wheel 90° so that the “X1” mark
the reverse order of disassembly. is positioned as shown.
ECA14130
NOTICE d. Release the front wheel.

e. When the front wheel stops, put an “X2” mark
Do not contact the wheel bearing inner race
“4” or balls “5”. Contact should be made at the bottom of the wheel.
only with the outer race “6”.
TIP
Use a socket “7” that matches the diameter of
the wheel bearing outer race and oil seal.
f. Repeat steps (c) through (e) several times

until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
EAS21970
• Front wheel static balance
ADJUSTING THE FRONT WHEEL STATIC
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
BALANCE a. Install a balancing weight “1” onto the rim ex-
TIP actly opposite the heavy spot “X”.
• After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
• Balancing weight(s)
2. Find:
• Front wheel’s heavy spot
TIP
Place the front wheel on a suitable balancing
stand. TIP
Start with the lightest weight.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
4-9
FRONT WHEEL
b. Turn the front wheel 90° so that the heavy

spot is positioned as shown.
2. Check:
• Front brake disc
Refer to “CHECKING THE FRONT BRAKE
c. If the heavy spot does not stay in that posi- DISC” on page 4-19.
tion, install a heavier weight. 3. Lubricate:
d. Repeat steps (b) and (c) until the front wheel • Wheel bearings
is balanced. • Oil seal lips
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Speedometer gear unit
4. Check: Recommended lubricant
• Front wheel static balance Lithium-soap-based grease
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays at
4. Install:
each position shown.
• Spacer
• Speedometer gear unit
• Front wheel
TIP
• Make sure the speedometer gear unit and the
wheel hub are installed with the two projections
meshed into the two slots respectively.
• Make sure that the slot “a” in the speedometer
gear unit fits over the stopper “b” on the front
fork outer tube.
• Install the tire and wheel with the mark “1”
b. If the front wheel does not remain stationary pointing in the direction of wheel rotation.
at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22000
INSTALLING THE FRONT WHEEL (FRONT

BRAKE DISC)
1. Install:
• Front brake disc
Front brake disc bolt

20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
LOCTITE®
4-10
FRONT WHEEL
5. Tighten:
• Front wheel axle
Front wheel axle

70 Nm (7.0 m·kg, 50 ft·lb)
T.
R.
EWA13500
WARNING
Make sure the brake hose is routed properly.
ECA2BK1010
NOTICE
Before tightening the wheel axle nut, push
down hard on the handlebars several times
and check if the front fork rebounds smooth-
ly.
6. Install:
• Front brake caliper
• Brake caliper bolts “1”
Front brake caliper bolt

35 Nm (3.5 m·kg, 25 ft·lb)
T.
R.
4-11
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear wheel
1
2
120 Nm (12.0 m • kg, 85 ft • lb)

T.R
.

Place the vehicle on the centerstand so that
the rear wheel is elevated.
Muffler Refer to “ENGINE REMOVAL” on page 5-1.
1 Rear wheel nut 1
2 Rear wheel 1
3 Washer 1
dure.
4-12
REAR WHEEL
EAS22070
REMOVING THE REAR WHEEL (DRUM) Rear wheel nut

1. Stand the vehicle on a level surface. 120 Nm (12.0 m·kg, 85 ft·lb)
T.
R.
EWA13120
WARNING
TIP
When tightening the rear wheel nut, fully
squeeze the rear brake lever so that the rear
TIP wheel does not turn.
Place the vehicle on the centerstand so that the 2. Adjust:
rear wheel is elevated. • Rear brake lever free play
2. Loosen: Refer to “ADJUSTING THE REAR DRUM
• Rear wheel nut BRAKE” on page 3-16.
TIP
When loosening the rear wheel nut, fully
squeeze the rear brake lever so that the rear
wheel does not turn.
EAS22090
CHECKING THE REAR WHEEL

1. Check:
• Tire
• Rear wheel
Refer to “CHECKING THE TIRES” on page
3-19 and “CHECKING THE WHEELS” on
page 3-21.
2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-8.
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm (0.04 in)
EAS22150
ADJUSTING THE REAR WHEEL STATIC

BALANCE
TIP
After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
1. Adjust:
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-9.
EAS22190
INSTALLING THE REAR WHEEL (DRUM)

1. Tighten:
• Rear wheel nut
4-13
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake pads
30 Nm (3.0 m•kg, 22 ft•Ib)
T.R
.
35 Nm (3.5 m•kg, 25 ft•Ib)
T.R
.

1 Brake caliper 1
2 Brake pad clip 2
3 Brake pad pin 1
4 Brake pad 2
5 Brake pad spring 1
dure.
4-14
FRONT BRAKE
Removing the front brake master cylinder
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.R
.
30 Nm (3.0 m • kg, 22 ft • Ib)

T.R
.

Handlebar cover 4-1.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
1 Front brake lever 1
2 Compression spring 1
3 Front brake light switch 1
4 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
5 1
er
6 Brake master cylinder reservoir diaphragm 1
7 Union bolt 1
8 Brake hose 1
9 Copper washer 2
10 Front brake master cylinder holder 1
11 Front brake master cylinder 1
12 Plate 1
dure.
4-15
FRONT BRAKE
Disassembling the front brake master cylinder
BF

1 Master cylinder kit 1
2 Master cylinder body 1
cedure.
4-16
FRONT BRAKE
Removing the front brake caliper
35 Nm (3.5 m • kg, 25 ft • Ib)

T.R
.
30 Nm (3.0 m • kg, 22 ft • Ib)

T.R
.

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Front brake caliper 1
dure.
4-17
FRONT BRAKE
Disassembling the front brake caliper

1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad 2
4 Brake pad spring 1
5 Brake caliper bracket 1
6 Brake caliper 1
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Bleed screw 1
cedure.
4-18
FRONT BRAKE
EAS22220
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
INTRODUCTION a. Place the vehicle on a suitable stand so that
EWA14100
the front wheel is elevated.
WARNING
b. Before measuring the front brake disc deflec-
Disc brake components rarely require disas- tion, turn the handlebar to the left or right to
sembly. Therefore, always follow these pre- ensure that the front wheel is stationary.
ventive measures: c. Remove the brake caliper.
• Never disassemble brake components un- d. Hold the dial gauge at a right angle against
less absolutely necessary. the brake disc surface.
• If any connection on the hydraulic brake e. Measure the deflection 3 mm (0.12 in) below
system is disconnected, the entire brake the edge of the brake disc.
system must be disassembled, drained,
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
cleaned, properly filled, and bled after reas-
sembly. 4. Measure:
• Never use solvents on internal brake com- • Brake disc thickness
ponents. Measure the brake disc thickness at a few dif-
• Use only clean or new brake fluid for clean- ferent locations.
ing brake components. Out of specification → Replace.
• Brake fluid may damage painted surfaces Brake disc thickness limit
and plastic parts. Therefore, always clean 3.5 mm (0.14 in)
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS22240
CHECKING THE FRONT BRAKE DISC

1. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-6. 5. Adjust:
2. Check: • Brake disc deflection
• Brake disc ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Damage/galling → Replace. a. Remove the brake disc.
3. Measure: b. Rotate the brake disc by one bolt hole.
• Brake disc deflection c. Install the brake disc.
Out of specification → Correct the brake disc Brake disc bolt
deflection or replace the brake disc. 20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
LOCTITE®
Brake disc deflection limit
0.15 mm (0.0059 in)
d. Measure the brake disc deflection.
4-19
FRONT BRAKE
e. If out of specification, repeat the adjustment

steps until the brake disc deflection is within Brake pad lining thickness (in-
specification. ner)
f. If the brake disc deflection cannot be brought 5.3 mm (0.21 in)
Limit
within specification, replace the brake disc.
0.8 mm (0.03 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Brake pad lining thickness (out-
6. Install: er)
• Front wheel 5.3 mm (0.21 in)
Refer to “FRONT WHEEL” on page 4-6. Limit
0.8 mm (0.03 in)
EAS22270
REPLACING THE FRONT BRAKE PADS

The following procedure applies to both brake
pad.
TIP
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Loosen:
• Brake caliper bolts “1”
4. Install:
• Brake pad spring “1”
• Brake pads “2”
TIP
Always install new brake pads and a brake pad
spring as a set.
2. Remove:
• Brake caliper
• Brake pads “1”
• Brake pad spring “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “3” tightly to the
bleed screw “4”. Put the other end of the hose
into an open container.
3
3. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
4-20
FRONT BRAKE
b. Loosen the bleed screw and push the brake

caliper pistons into the brake caliper with your
finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
d. Install new brake pads and a new brake pad

spring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
5. Install:
• Brake caliper Put the end of the brake hose into a container
• Brake caliper bolts and pump out the brake fluid carefully.
Front brake caliper bolt EAS22340
35 Nm (3.5 m·kg, 25 ft·lb) DISASSEMBLING THE FRONT BRAKE

T.
R.
CALIPER
6. Check: 1. Remove:
• Brake fluid level • Brake caliper piston “1”
Below the minimum level mark “a” → Add the • Brake caliper piston dust seal “2”
recommended brake fluid to the proper level. • Brake caliper piston seal “3”
Refer to “CHECKING THE BRAKE FLUID
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the brake caliper piston with a piece
of wood “a”.
7. Check: b. Blow compressed air into the brake hose joint
• Brake lever operation opening “b” to force out the piston from the
Soft or spongy feeling → Bleed the brake sys- brake caliper.
tem.
Refer to “BLEEDING THE HYDRAULIC
EAS22300
REMOVING THE FRONT BRAKE CALIPER

TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Union bolt “1” EWA2BK1009
• Copper washers “2” WARNING

• Brake hose “3” Never try to pry out the brake caliper piston.
c. Remove the brake caliper piston dust seal
and the brake caliper piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-21
FRONT BRAKE
EAS22390 EAS22410
CHECKING THE FRONT BRAKE CALIPER ASSEMBLING THE FRONT BRAKE CALIPER
EWA2BK1004
Recommended brake component replace- WARNING
ment schedule
• Before installation, all internal brake com-
Brake pads If necessary ponents should be cleaned and lubricated
Piston seal Every two years with clean or new brake fluid.
• Never use solvents on internal brake com-
Piston dust seal Every two years
ponents as they will cause the brake caliper
Brake hose Every four years piston dust seal and the brake caliper pis-
Every two years and ton seal to swell and distort.
Brake fluid whenever the brake • Whenever a brake caliper is disassembled,
is disassembled replace the brake caliper piston dust seal
and the brake caliper piston seal.
1. Check:
• Brake caliper piston “1”
Specified brake fluid
Rust/scratches/wear → Replace the brake DOT 3 or 4
caliper piston.
• Brake caliper cylinder “2” 1. Install:
Scratches/wear → Replace the brake caliper
assembly. • Brake caliper piston seal “1” New
• Brake caliper body “3” • Brake caliper piston dust seal “2” New
Cracks/damage → Replace the brake caliper • Brake caliper piston “3”
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
2. Install:
• Brake caliper bracket
EWA2BK1011 EAS22440
WARNING INSTALLING THE FRONT BRAKE CALIPER

Whenever a brake caliper is disassembled, 1. Install:
replace the piston seal. • Brake pad spring
• Brake pads
2. Check: • Brake pad pin
• Brake caliper bracket “1” • Brake pad clip
Cracks/damage → Replace. • Brake caliper
• Brake caliper bolt
Front brake caliper bolt

35 Nm (3.5 m·kg, 25 ft·lb)
T.
R.
Refer to “REPLACING THE FRONT BRAKE

PADS” on page 4-20.
2. Install:
• Copper washers “1” New
4-22
FRONT BRAKE
• Union bolt “3” • Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
Brake hose union bolt
any spilt brake fluid immediately.
30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
4. Bleed:
EWA13530
• Brake system
WARNING
Proper brake hose routing is essential to in- BRAKE SYSTEM” on page 3-17.
sure safe vehicle operation. Refer to “CABLE 5. Check:
ROUTING” on page 2-25. • Brake fluid level
ECA14170 Below the minimum level mark “a” → Add the
NOTICE recommended brake fluid to the proper level.
When installing the brake hose onto the Refer to “BLEEDING THE HYDRAULIC
brake caliper “1”, make sure the brake pipe BRAKE SYSTEM” on page 3-17.
“a” touches the projection “b” on the brake
caliper.
a
6. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
3. Fill:
tem.
• Brake master cylinder reservoir
(With the specified amount of the recom-
mended brake fluid)
EAS22490
Specified brake fluid REMOVING THE FRONT BRAKE MASTER

DOT 3 or 4 CYLINDER
EWA13090
TIP
WARNING Before removing the front brake master cylinder,
• Use only the designated brake fluid. Other drain the brake fluid from the entire brake sys-
brake fluids may cause the rubber seals to tem.
deteriorate, causing leakage and poor 1. Disconnect:
brake performance. • Front brake light switch “1”
4-23
FRONT BRAKE
TIP
Push the fastener to remove the front brake light
switch from the brake master cylinder.
3. Check:
• Brake master cylinder reservoir cap “1”
• Brake master cylinder reservoir diaphragm
holder “2”
• Brake master cylinder reservoir diaphragm
2. Remove: “3”
• Union bolt “1” Damage/wear → Replace.
• Copper washers “2”
TIP
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
4. Check:
• Brake hose
EAS22520
ASSEMBLING THE FRONT BRAKE MASTER

CYLINDER
EWA13520
WARNING
EAS22500
CHECKING THE FRONT BRAKE MASTER • Before installation, all internal brake com-
CYLINDER ponents should be cleaned and lubricated
1. Check: with clean or new brake fluid.
• Brake master cylinder “1” • Never use solvents on internal brake com-
Damage/scratches/wear → Replace. ponents.
• Brake fluid delivery passages
(brake master cylinder body) Specified brake fluid
Obstruction → Blow out with compressed air. DOT 3 or 4
1. Install:
• Brake master cylinder kit “1” New
2. Check:
• Brake master cylinder kit “1”
Damage/scratches/wear → Replace.
4-24
FRONT BRAKE
EAS22530
• Turn the handlebar to the left and right to make
INSTALLING THE FRONT BRAKE MASTER
sure the brake hose does not touch other parts
CYLINDER
(e.g., wire harness, cables, leads). Correct if
1. Install:
necessary.
• Front brake master cylinder “1”
• Front brake master cylinder holder “2”
Front brake master cylinder hold-

er bolt
T.
R.
9 Nm (0.9 m·kg, 6.5 ft·lb)
TIP
• Install the front brake master cylinder holder
with the “UP” mark facing up.
• Align the end of the front brake master cylinder
holder with the punch mark “a” on the handle- 3. Fill:
bar. • Brake master cylinder reservoir
• First, tighten the upper bolt, then the lower bolt. (With the specified amount of the recom-
mended brake fluid)
Specified brake fluid

DOT 3 or 4
EWA13540
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
2. Install: • Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
• Copper washers New may result in a harmful chemical reaction,
• Brake hose leading to poor brake performance.
• Union bolt • When refilling, be careful that water does
Brake hose union bolt not enter the brake master cylinder reser-
30 Nm (3.0 m·kg, 22 ft·lb) voir. Water will significantly lower the boil-
T.
R.
ing point of the brake fluid and could cause

EWA13530 vapor lock.
WARNING ECA13540
Proper brake hose routing is essential to in- NOTICE

sure safe vehicle operation. Refer to “CABLE Brake fluid may damage painted surfaces
ROUTING” on page 2-25. and plastic parts. Therefore, always clean up
ECA2BK1016 any spilt brake fluid immediately.
NOTICE
4. Bleed:
When installing the brake hose onto the • Brake system
brake master cylinder, make sure the brake Refer to “BLEEDING THE HYDRAULIC
pipe touches the projection “a” on the brake BRAKE SYSTEM” on page 3-17.
master cylinder. 5. Check:
TIP • Brake fluid level
• While holding the brake hose, tighten the union Below the minimum level mark “a” → Add the
bolt as shown. recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
4-25
FRONT BRAKE
6. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
4-26
REAR BRAKE
EAS2BK1020
REAR BRAKE
Removing the rear brake shoe
LS
11
10
7
LS
9
6
3
5
4
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.

Place the vehicle on the centerstand so that
the rear wheel is elevated.
Rear wheel Refer to “REAR WHEEL” on page 4-12.
1 Brake shoe 2
2 Brake shoe spring 2
3 Brake cable adjusting nut 1
5 Brake cable assembly 1
6 Pin 1
7 Brake camshaft lever bolt 1
8 Brake camshaft lever 1
9 Brake shoe wear indicator 1
10 Brake camshaft 1
11 O-ring 2
dure.
4-27
REAR BRAKE
EAS2BK1017
REMOVING THE REAR BRAKE TIP

1. Remove: After sanding the glazed areas, clean the brake
• Brake shoes “1” shoe with a cloth.
• Brake shoe springs “2”
2. Measure:
2. Remove: • Brake shoe lining thickness “a”
• Adjusting nut “1” Out of specification → Replace.
• Brake cable “2”
• Pin “3” Lining thickness
• Brake camshaft lever bolt “4” 4.0 mm (0.16 in)
• Brake camshaft lever “5” Limit
• Brake shoe wear indicator “6” 2.0 mm (0.08 in)
4
2 5
3 1
3. Remove:
EWA2BK1006
• Brake camshaft “1”
WARNING
Do not allow oil or grease on the brake
shoes.
TIP
Replace the brake shoes as a set, if either is
worn to the wear limit.
3. Measure:
• Brake drum inside diameter “a”
Out of specification → Replace the wheel.
EAS2BK1018
CHECKING THE REAR BRAKE SHOES Brake drum inside diameter

1. Check: 110.0 mm (4.33 in)
• Brake shoe lining Limit
Glazed areas → Repair. 111.0 mm (4.37 in)
Sand the glazed areas with coarse sandpa-
per.
4-28
REAR BRAKE
Brake camshaft lever bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
TIP
• Align the punch mark on the brake camshaft
with the mark on the brake camshaft lever po-
sitioned as shown “a”.
• When installing the brake camshaft lever to the
brake camshaft, shift the brake camshaft lever
4. Check: punch mark half a serration down from the
• Brake drum inner surface point where the brake camshaft punch mark
Oil deposits → Clean. “b” and the brake camshaft lever punch mark
Remove the oil with a rag soaked in lacquer “c” meet.
thinner or solvent.
Scratches → Repair.
Lightly and evenly polish the scratches with
an emery cloth.
5. Check:
• Brake camshaft
EAS2BK1019
ASSEMBLING THE REAR BRAKE SHOE

PLATE
1. Install:
• Brake camshaft “1”
• Brake shoe wear indicator “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the brake camshaft so its punch mark
“a” is positioned as shown.
b. Align the projection “b” on the brake shoe
wear indicator with the notch in the brake
camshaft.
c. Check that the brake shoes are properly po-
sitioned. A. Function
EWA2BK1007
B. Malfunction
WARNING
After installing the brake camshaft, remove 3. Install:
any excess grease. • Brake shoe spring “1”
• Brake shoes
TIP
• Lubricate the pivot pin with a thin coat of lithi-
um-soap-based grease.
• Do not damage the springs during installation.
• Install the brake shoe springs as shown.
EWA2BK1008
WARNING
Do not apply grease to the brake shoe lin-
ings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Brake camshaft lever “1”
4-29
REAR BRAKE
4-30
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.R
.
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T.R
.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.R
.
60 Nm (6.0 m • kg, 43 ft • Ib)

T.R
.

Handlebar cover 4-1.
1 Plastic band 1
2 Front brake master cylinder holder 1
3 Front brake master cylinder assembly 1
4 Throttle cable housing 2
5 Throttle cable 2 Disconnect.
6 Throttle grip 1
7 Rear brake light switch 1
8 Brake cable 1 Disconnect.
9 Rear brake lever 1
10 Handlebar grip 1
11 Handlebar 1
dure.
4-31
HANDLEBAR
EAS22860
REMOVING THE HANDLEBAR Handlebar nut

T.
R.
EWA13120
WARNING
2. Remove:
• Handlebar grip “1”
TIP
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
3. Install:
• Handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
EWA13700
WARNING
EAS22880
CHECKING THE HANDLEBAR Do not touch the handlebar grip until the rub-
1. Check: ber adhesive has fully dried.
• Handlebar “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Bends/cracks/damage → Replace. 4. Install:
EWA13690
WARNING • Rear brake lever

• Brake cable
Do not attempt to straighten a bent handle-
• Rear brake light switch
bar as this may dangerously weaken it.
5. Install:
• Throttle grip
• Throttle cables
(Apply the lithium-soap-based grease)
• Throttle cable housing “1”
TIP
Align the projections “a” on the throttle cable
housing with the holes “b” in the handlebar.
EAS22930
INSTALLING THE HANDLEBAR

EWA13120
WARNING
2. Install:
• Handlebar “1”
4-32
HANDLEBAR
6. Install:
• Front brake master cylinder
Refer to “INSTALLING THE FRONT BRAKE
MASTER CYLINDER” on page 4-25.
7. Adjust:
• Throttle grip free play

3.0–5.0 mm (0.12–0.20 in)
4-33
FRONT FORK
EAS22950
FRONT FORK
Removing the front fork legs
1st 30 Nm (3.0 m • kg, 22 ft • lb) 65 Nm (6.5 m • kg, 47 ft • Ib)
T.R
.
T.R
2nd 65 Nm (6.5 m • kg, 47 ft • lb)

.
3 6 New
7
7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
T.R
T.R
.

Leg shield 4-1.
Front wheel Refer to “FRONT WHEEL” on page 4-6.
1 Front fender 1
2 Speedometer cable guide 1
3 Brake hose guide 1
4 Lower bracket pinch bolt 1 Loosen.
5 Cap bolt 1
6 O-ring 1
7 Front fork leg 1
dure.
4-34
FRONT FORK
Disassembling the front fork legs
7 2
10
New 11
12 8
New 5
9
LT 4
30 Nm (3.0 m • kg, 22 ft • Ib)
T.R
.

1 Dust boot band 1
2 Dust boot 1
3 Fork spring 1
4 Damper rod assembly bolt 1
5 Copper washer 1
6 Damper rod 1
7 Rebound spring 1
8 Inner tube 1
9 Oil lock piece 1
10 Oil seal clip 1
11 Oil seal 1
12 Outer tube 1
cedure.
4-35
FRONT FORK
EAS22960
3. Drain:
REMOVING THE FRONT FORK LEGS
• Fork oil
front fork legs.
EWA13120
WARNING
TIP
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Remove: 4. Remove:
• Cap bolt “1” • Damper rod bolt “1”
(Use the 14 mm hexagon wrench) • Copper washer
3. Loosen: TIP
• Lower bracket pinch bolts “2” While holding the damper rod with the damper
rod holder “2” and T-handle “3”, loosen the
damper rod bolt.
T-handle
90890-01326
YM-01326
Damper rod holder
90890-01294
EWA13640 YM-01300
WARNING
Before loosening the lower bracket pinch
bolts, support the front fork leg.
4. Remove:
• Front fork leg
EAS22980
DISASSEMBLING THE FRONT FORK LEGS

front fork legs.
1. Remove: 5. Remove:
• Dust boot band “1” • Damper rod
• Dust boot “2” • Rebound spring
6. Remove:
• Inner tube
• Oil lock piece
ECA2BK1011
NOTICE
Do not scratch the inner tube.
7. Remove:
• Oil seal circlip “1”
(with a flat-head screwdriver)
2. Remove:
• Fork spring
4-36
FRONT FORK
ECA2BK1012
2. Measure:
NOTICE • Spring free length “a”
Do not scratch the outer tube. Out of specification → Replace.
Fork spring free length

227.0 mm (8.94 in)
Limit
222.0 mm (8.74 in)
8. Remove:
• Oil seal “1”
ECA2BK1013
NOTICE
Oil seal cannot be repeatedly used.
3. Check:
• Damper rod “1”
2 Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil lock piece “2”
1 Damage → Replace.
2. Cloth
EAS23010
CHECKING THE FRONT FORK LEGS

front fork legs.
EAS23020
1. Check:
ASSEMBLING THE FRONT FORK LEGS
• Inner tube “1”
• Outer tube “2”
front fork legs.
Bends/damage/scratches → Replace. EWA13660
EWA13650
WARNING
WARNING
• Make sure the oil levels in both front fork
Do not attempt to straighten a bent inner
legs are equal.
tube as this may dangerously weaken it.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
2 –Oil seal
–Copper washer
1 –O-ring (Cap bolt)
• Before assembling the front fork leg, make
sure all of the components are clean.
4-37
FRONT FORK
1. Install:
• Damper rod “1”
• Rebound spring “2”
ECA14210
NOTICE
Allow the damper rod assembly to slide
slowly down the inner tube “3” until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
4. Install:
• Oil seal “1” New
(with the fork seal driver “2” and attachment
“3”)
Fork seal driver weight

90890-01367
Replacement hammer
YM-A9409-7
2. Lubricate: Fork seal driver attachment (ø30)
• Inner tube’s outer surface 90890-01400
ECA14220
Recommended oil
NOTICE
Fork oil 10W or equivalent
Make sure the numbered side of the oil seal
3. Install: faces up.
• Oil lock piece
TIP
• Inner tube
(into the outer tube) • Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Copper washer New • Lubricate the outer surface of the inner tube
• Damper rod assembly bolt “1” with fork oil.
Damper rod assembly bolt • Before installing the oil seal, cover the top of
30 Nm (3.0 m·kg, 22 ft·lb) the front fork leg with a plastic bag “4” to protect
T.
the oil seal during installation.

R.
LOCTITE®
TIP
While holding the damper rod assembly with the
damper rod holder “2” and T-handle “3”, tighten
the damper rod assembly bolt.
T-handle
90890-01326
YM-01326
Damper rod holder
90890-01294
YM-01300
4-38
FRONT FORK
5. Install: 8. Install:
• Oil seal clip “1” • Fork spring “1”
TIP TIP
Adjust the oil seal clip so that it fits into the outer Install the spring with the smaller pitch facing up.
tube’s groove.
9. Install:
6. Fill: • Dust boot “1”
• Front fork leg • Dust boot band “2”
mended fork oil)
Recommended oil
Fork oil 10W or equivalent
Quantity
83.5 cm³ (2.82 US oz, 2.94
Imp.oz)
TIP
EAS23060
• While filling the front fork leg, keep it upright. INSTALLING THE FRONT FORK LEGS
• After filling, slowly pump the front fork leg up The following procedure applies to both of the
and down to distribute the fork oil. front fork legs.
7. Measure: 1. Install:
• Front fork leg oil level “a” • Front fork leg
(from the top of the inner tube, with the inner • O-ring New
tube fully compressed and without the fork • Cap bolt
spring) TIP
Out of specification → Correct. Pull up the inner tube until it stops, then install
the cap bolt.
Level
84.6 mm (3.33 in) 2. Tighten:
• Lower bracket pinch bolt “1”
4-39
FRONT FORK
Lower bracket pinch bolt

30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
• Front fork cap bolt “2”
Front fork cap bolt

65 Nm (6.5 m·kg, 47 ft·lb)
T.
R.
• Lower bracket pinch bolt “1”
Lower bracket pinch bolt

65 Nm (6.5 m·kg, 47 ft·lb)
T.
R.
4-40
STEERING HEAD
EAS23090
STEERING HEAD
Removing the lower bracket
11
75 Nm (7.5 m • kg, 54 ft • Ib)
12
T.R
.
13
8
LS
9
10
LS 1
6
2
3
14 4
5
1st 38 Nm (3.8 m • kg, 27 ft • lb)

T.R
2nd 12 Nm (1.2 m • kg, 8.7 ft • lb)

.

Front fork leg Refer to “FRONT FORK” on page 4-34.
Handlebar Refer to “HANDLEBAR” on page 4-31.
1 Upper ring nut 1
2 Lock washer 1
3 Center ring nut 1
4 Rubber washer 1
5 Lower ring nut 1
6 Lower bracket 1
7 Bearing cover 1
8 Bearing race 1 1
9 Upper bearing 1
10 Bearing race 2 1
11 Bearing race 3 1
12 Lower bearing 1
13 Bearing race 4 1
4-41
STEERING HEAD
Removing the lower bracket
11
75 Nm (7.5 m • kg, 54 ft • Ib)
12
T.R
.
13
8
LS
9
10
LS 1
6
2
3
14 4
5
1st 38 Nm (3.8 m • kg, 27 ft • lb)

T.R
2nd 12 Nm (1.2 m • kg, 8.7 ft • lb)

.

14 Rubber washer 1
dure.
4-42
STEERING HEAD
EAS23110 EAS23120
REMOVING THE LOWER BRACKET CHECKING THE STEERING HEAD

1. Stand the vehicle on a level surface. 1. Wash:
EWA13120
• Bearings
WARNING • Bearing races
no danger of it falling over. Recommended cleaning solvent
Kerosene
2. Remove:
• Upper ring nut “1” 2. Check:
• Lock washer “2” • Bearings “1”
• Center ring nut “3” • Bearing races “2”
• Rubber washer Damage/pitting → Replace.
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
3. Replace:
• Bearings
• Bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing race “1” from the steer-
3. Remove: ing head pipe with a long rod “2” and ham-
• Lower ring nut “1” mer.
(Use the ring nut wrench “2”) b. Remove the bearing race “4” from the lower
• Lower bracket bracket with a floor chisel “3” and hammer.
c. Install a new rubber seal and new bearing
Ring nut wrench races.
90890-01268
Spanner wrench 2
YU-01268
4 3
EWA13730
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
4-43
STEERING HEAD
ECA14270
NOTICE
If the bearing race is not installed properly,
the steering head pipe could be damaged.
TIP
• Always replace the bearings and bearing races
as a set.
• Whenever the steering head is disassembled,
replace the rubber seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
EAS23150
INSTALLING THE LOWER BRACKET

1. Lubricate:
• Upper bearing
• Lower bearing
• Bearing races
2. Wash:
• All ring nuts
• Lower bracket
TIP
Clean the area “a” of the lower bracket indicated
in the illustration.
3. Install:
• Lower bracket
• Lower ring nut “1”
• Rubber washer “2”
• Center ring nut “3”
• Lock washer “4”
• Upper ring nut “5”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-18.
4-44
REAR SHOCK ABSORBER ASSEMBLY
EAS23160

Removing the rear shock absorber assembly
33 Nm (3.3 m • kg, 24 ft • Ib)

T.R
.
18 Nm (1.8 m • kg, 13 ft • Ib)

T.R
.

Air filter case 4-1.
1 Rear shock absorber assembly 1
dure.
4-45
EAS23220
REMOVING THE REAR SHOCK ABSORBER Rear shock absorber assembly

ASSEMBLY upper nut
T.
R.
EWA13120
WARNING lower bolt
Securely support the vehicle so that there is 18 Nm (1.8 m·kg, 13 ft·lb)
TIP
Place the vehicle on the centerstand so that the
rear wheel is elevated.
2. Remove:
• Air filter case
• Rear shock absorber assembly “1”
2. Install:
• Air filter case
EAS23240
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• Rear shock absorber
Oil leaks → Replace the rear shock absorber
assembly.
• Spring
Damage/wear → Replace the rear shock ab-
sorber assembly.
• Bolts
Bends/damage/wear → Replace.
EAS23320
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Install:
• Rear shock absorber assembly upper nut “1”
• Rear shock absorber assembly lower bolt “2”
4-46
4-47
ENGINE
ENGINE REMOVAL ........................................................................................5-1

INSTALLING THE ENGINE....................................................................... 5-4
CYLINDER HEAD............................................................................................ 5-5

REMOVING THE CYLINDER HEAD.........................................................5-7
CHECKING THE CYLINDER HEAD .........................................................5-8
CHECKING THE CAMSHAFT SPROCKET..............................................5-8
CHECKING THE TIMING CHAIN TENSIONER........................................ 5-9
INSTALLING THE CYLINDER HEAD .......................................................5-9
CAMSHAFT ................................................................................................... 5-12

REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 5-13
CHECKING THE CAMSHAFT.................................................................5-13
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-14
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-15
VALVES AND VALVE SPRINGS.................................................................. 5-17

REMOVING THE VALVES...................................................................... 5-18
CHECKING THE VALVES AND VALVE GUIDES ..................................5-18
CHECKING THE VALVE SEATS ............................................................ 5-20
CHECKING THE VALVE SPRINGS........................................................ 5-21
INSTALLING THE VALVES .................................................................... 5-22
CYLINDER AND PISTON.............................................................................. 5-24

5
REMOVING THE CYLINDER AND PISTON...........................................5-25
CHECKING THE CYLINDER AND PISTON ...........................................5-25
CHECKING THE PISTON RINGS........................................................... 5-26
CHECKING THE PISTON PIN ................................................................5-27
CHECKING THE TIMING CHAIN GUIDE ............................................... 5-27
INSTALLING THE PISTON AND CYLINDER .........................................5-27
AC MAGNETO ROTOR................................................................................. 5-29

REMOVING THE AC MAGNETO ROTOR.............................................. 5-30
INSTALLING THE AC MAGNETO ROTOR ............................................5-30
KICKSTARTER ............................................................................................. 5-31

CHECKING THE KICKSTARTER ........................................................... 5-33
INSTALLING THE KICKSTARTER ......................................................... 5-33
V-BELT AUTOMATIC TRANSMISSION .......................................................5-34
REMOVING THE PRIMARY SHEAVE....................................................5-36
REMOVING THE SECONDARY SHEAVE ............................................. 5-36
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-36
CHECKING THE CLUTCH HOUSING ....................................................5-37
CHECKING THE CLUTCH SHOES ........................................................ 5-37
CHECKING THE V-BELT........................................................................5-37
CHECKING THE PRIMARY SHEAVE ....................................................5-38
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-38
CHECKING THE SLIDERS ..................................................................... 5-38
CHECKING THE SECONDARY SHEAVE .............................................. 5-38
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-39
ASSEMBLING THE SECONDARY SHEAVE..........................................5-39
INSTALLING THE V-BELT...................................................................... 5-40
STARTER CLUTCH ......................................................................................5-43

CHECKING THE STARTER CLUTCH ....................................................5-44
INSTALLING THE STARTER CLUTCH .................................................. 5-44
ELECTRIC STARTER ...................................................................................5-46

CHECKING THE STARTER MOTOR .....................................................5-48
ASSEMBLING THE STARTER MOTOR................................................. 5-49
INSTALLING THE STARTER MOTOR ...................................................5-49
OIL PUMP...................................................................................................... 5-50

CHECKING THE OIL PUMP ................................................................... 5-51
ASSEMBLING THE OIL PUMP...............................................................5-51
INSTALLING THE OIL PUMP .................................................................5-52
CRANKCASE ................................................................................................5-53
DISASSEMBLING THE CRANKCASE....................................................5-55
CHECKING THE CRANKCASE ..............................................................5-55
CHECKING THE TIMING CHAIN AND CHAIN GUIDE .......................... 5-55
ASSEMBLING THE CRANKCASE.......................................................... 5-55
CRANKSHAFT ASSEMBLY .........................................................................5-57

REMOVING THE CRANKSHAFT ASSEMBLY ....................................... 5-58
CHECKING THE CRANKSHAFT ASSEMBLY........................................ 5-58
INSTALLING THE CRANKSHAFT ASSEMBLY...................................... 5-58
TRANSMISSION............................................................................................ 5-60
CHECKING THE TRANSMISSION ......................................................... 5-61
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the muffler
31 Nm (3.1 m • kg, 22 ft • Ib)

T.R
.
13 Nm (1.3 m • kg, 9.4 ft • Ib)

2 New
T.R
.

1 Muffler 1
2 Exhaust gasket 1
dure.
5-1
ENGINE REMOVAL
Removing the engine
55 Nm (5.5 m • kg, 40 ft • Ib)

T.R
.
13
18 Nm (1.8 m • kg, 13 ft • Ib)
T.R
.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.R
.
8
12
4
6
7 3
1 5
13
17 16
9
10
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
15 14
48 Nm (4.8 m • kg, 35 ft • Ib)
T.R
.

Seat/Storage compartment/Front cover/Rear Refer to “GENERAL CHASSIS” on page
cover/Left and right side cover 4-1.
Carburetor Refer to “CARBURETOR” on page 6-3.
1 V-belt case air duct 1 Disconnect.
2 Spark plug cap 1 Disconnect.
Disconnect.
3 Air induction system vacuum hose 1 For air induction system models
4 Fuel cock vacuum hose 1 Disconnect.
5 AC magneto assembly coupler 2 Disconnect.
6 Starter motor lead 1 Disconnect.
7 Engine ground lead 1 Disconnect.
Air induction system hose (reed valve assembly Disconnect.
8 1
to cylinder head) For air induction system models
9 Brake cable 1 Disconnect.
10 Centerstand lock cover 1
11 Centerstand lock cable 1 Disconnect.
12 Rear shock absorber lower bolt 1
13 Engine bracket bolt/nut 1/1
5-2
ENGINE REMOVAL
Removing the engine
55 Nm (5.5 m • kg, 40 ft • Ib)

T.R
.
13
18 Nm (1.8 m • kg, 13 ft • Ib)
T.R
.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.R
.
8
12
4
6
7 3
1 5
13
17 16
9
10
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
15 14
48 Nm (4.8 m • kg, 35 ft • Ib)
T.R
.

14 Centerstand spring 1
15 Centerstand 1
16 Centerstand lock assembly 1
17 Engine bracket 1 1
dure.
5-3
ENGINE REMOVAL
EAS23720
INSTALLING THE ENGINE

1. Install:
• Engine bracket bolt/nut “1”
• Rear shock absorber lower bolt “2”
TIP
Do not fully tighten the bolt and nut.
2. Tighten:
• Engine bracket nut
• Rear shock absorber lower bolt
Engine bracket nut

55 Nm (5.5 m·kg, 40 ft·lb)
T.
R.

lower bolt
18 Nm (1.8 m·kg, 13 ft·lb)
5-4
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.R
.
2 Nm (0.2 m • kg, 1.4 ft • Ib)
T.R
.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.R
.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
7 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
11 18 Nm (1.8 m • kg, 13 ft • Ib)
T.R
.
4
5
13 Nm (1.3 m • kg, 9.4 ft • Ib)

T.R
.
9 16
14
15
1 2
8
3
13
9 12 6
10
18 Nm (1.8 m • kg, 13 ft • Ib) 29 Nm (2.9 m • kg, 21 ft • Ib)
T.R
T.R
.
22 Nm (2.2 m • kg, 16 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
T.R
.
12 Nm (1.2 m • kg, 8.7 ft • Ib) 12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.R
T.R
.
.

Seat/Storage compartment/Front cover/Rear Refer to “GENERAL CHASSIS” on page
cover/Left and right side cover 4-1.
Carburetor Refer to “CARBURETOR” on page 6-3.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1
Disconnect.
3 Air induction system pipe 1 For air induction system models
4 Intake manifold 1
5 Intake manifold joint 1
6 Cylinder head breather hose 1 Disconnect.
7 Air shroud (right side) 1
8 Air shroud (left side) 1
9 Tappet cover 2
10 Cylinder head breather assembly 1
11 Timing chain tensioner assembly 1
5-5
CYLINDER HEAD
Removing the cylinder head
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.R
.
2 Nm (0.2 m • kg, 1.4 ft • Ib)
T.R
.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.R
.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
7 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
11 18 Nm (1.8 m • kg, 13 ft • Ib)
T.R
.
4
5
13 Nm (1.3 m • kg, 9.4 ft • Ib)

T.R
.
9 16
14
15
1 2
8
3
13
9 12 6
10
18 Nm (1.8 m • kg, 13 ft • Ib) 29 Nm (2.9 m • kg, 21 ft • Ib)
T.R
T.R
.
22 Nm (2.2 m • kg, 16 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
T.R
.

T.R
T.R
.
.

12 Camshaft sprocket plate 1
13 Camshaft sprocket 1
14 Rear shock absorber lower bolt 1
15 Cylinder head 1
16 Cylinder head gasket 1
dure.
5-6
CYLINDER HEAD
EAS24130
REMOVING THE CYLINDER HEAD

1. Align:
• “I” mark “a” on the AC magneto rotor (with the
stationary pointer “b” on the right crankcase)
b
a
3. Remove:
• Timing chain tensioner cap bolt “1”
• Timing chain tensioner “2”
• Gasket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark “c” on the cam-
shaft sprocket with the mark “d” on the
cylinder head.
4. Remove:
• Camshaft sprocket plate
• Camshaft sprocket
TIP
To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Remove:
2. Loosen: • Cylinder head bolts
• Camshaft sprocket bolt “1” • Cylinder head nuts
TIP • Cylinder head
While holding the AC magneto rotor nut with a TIP
wrench “2”, loosen the camshaft sprocket bolt. • Loosen the bolts and nuts in the proper se-
quence as shown.
• Loosen each nut 1/2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
• When removing the cylinder head, remove the
rear shock absorber lower bolt first and then lift
up the back of the vehicle so that the cylinder
head does not touch the frame.
5-7
CYLINDER HEAD
EAS24160 b. Measure the warpage.

CHECKING THE CYLINDER HEAD c. If the limit is exceeded, resurface the cylinder
1. Eliminate: head as follows.
• Combustion chamber carbon deposits d. Place a 400–600 grit wet sandpaper on the
(with a rounded scraper) surface plate and resurface the cylinder head
TIP using a figure-eight sanding pattern.
Do not use a sharp instrument to avoid damag- TIP
ing or scratching: To ensure an even surface, rotate the cylinder
• Spark plug bore threads head several times.
• Valve seats
e. After resurfacing, out of specification → Re-

2. Check: place the cylinder head.
• Cylinder head ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Damage/scratches → Replace. EAS2BK1022
3. Measure: CHECKING THE CAMSHAFT SPROCKET

• Cylinder head warpage 1. Check:
Out of specification → Resurface the cylinder • Camshaft sprocket
head. More than 1/4 tooth wear “a” → Replace the
camshaft sprocket, timing chain and crank-
Warpage limit shaft as a set.
0.05 mm (0.0020 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
5-8
CYLINDER HEAD
EAS24230
INSTALLING THE CYLINDER HEAD

1. Install:
• Cylinder head gasket New
• Dowel pins
2. Install:
• Cylinder head
• Copper washers New
TIP
• Pass the timing chain through the timing chain
a. 1/4 tooth
cavity.
b. Correct
• When installing the cylinder head, remove the
1. Timing chain roller
rear shock absorber lower bolt first and then lift
2. Camshaft sprocket
up the back of the vehicle so that the cylinder
EAS24190 head does not touch the frame.
CHECKING THE TIMING CHAIN TENSIONER
3. Tighten:
1. Check:
• Cylinder head nuts
• Timing chain tensioner
• Cylinder head bolts
Cylinder head nut
22 Nm (2.2 m·kg, 16 ft·lb)
T.
R.
Cylinder head bolt

12 Nm (1.2 m·kg, 8.7 ft·lb)
TIP
Tighten the cylinder head bolts and nuts in the
proper tightening sequence as shown.
2. Check:
• One-way cam operation
Rough movement → Replace the timing
chain tensioner assembly.
3. Check:
• Cap bolt “1”
• O-ring “2”
• Spring “3”
• One-way cam “4”
• Timing chain tensioner rod “5” 4. Install:
Damage/wear → Replace the timing chain • Camshaft sprocket “1”
tensioner assembly. • Camshaft sprocket plate “2”
• Camshaft sprocket bolt “3”
(with the camshaft sprocket temporarily tight-
ened)
5-9
CYLINDER HEAD
f. Remove the wire from the timing chain.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Timing chain tensioner gasket New
• Timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove cap bolt “1” and spring “2”.
b. Push down the one-way cam “3” of the timing
chain tensioner and fully insert the tensioner
rod “4” inside of the tensioner housing.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. Align the “I” mark “a” on the AC magneto rotor
with the stationary pointer “b” on the right
crankcase.
c. Align the “I” mark “c” on the camshaft sprock-
et with the mark “d” on the cylinder head.
d. Install the timing chain “2” onto the camshaft
sprocket “1”, and then install the camshaft
sprocket onto the camshaft.
c. Install the timing chain tensioner and the gas-
ket “5” onto the cylinder.
d. Apply a sealant to the front side of the timing
b
chain tensioner assembly bolt.
a
Yamaha bond No. 1215
90890-85505
Timing chain tensioner assem-

bly bolt
T.
R.
10 Nm (1.0 m·kg, 7.2 ft·lb)
e. Install the spring and the timing chain ten-

sioner cap bolt.
Timing chain tensioner assem-

bly cap bolt
T.
R.
7 Nm (0.7 m·kg, 5.1 ft·lb)
TIP
When installing the camshaft sprocket, be sure
to keep the timing chain as tight as possible on
the exhaust side.
ECA2BK1014
NOTICE
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
e. While holding the camshaft, temporarily tight-

en the camshaft sprocket bolt.
5-10
CYLINDER HEAD
6. Turn:
• Crankshaft
(several turns clockwise)
7. Check:
• “I” mark “a”
Align the “I” mark on the AC magneto rotor
with the stationary pointer “b” on the right
crankcase.
• “I” mark “c”
Align the “I” mark on the camshaft sprocket
with the mark “d” on the cylinder head.
Out of alignment → Correct.
Refer to the installation steps above.
b
a
8. Tighten:
• Camshaft sprocket bolt
Camshaft sprocket bolt

29 Nm (2.9 m·kg, 21 ft·lb)
T.
R.
ECA13750
NOTICE
Be sure to tighten the camshaft sprocket bolt
to the specified torque to avoid the possibil-
ity of the bolt coming loose and damaging
the engine.
9. Measure:
• Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4.
5-11
CAMSHAFT
EAS23730
CAMSHAFT
Removing the rocker arms and camshaft
T.R
T.R
.
.
1
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.R
.
1 2
2
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.R
.
3
13 Nm (1.3 m • kg, 9.4 ft • Ib)

T.R
.

Cylinder head Refer to “CYLINDER HEAD” on page 5-5.
1 Locknut 2 Loosen.
2 Adjusting screw 2 Loosen.
3 Camshaft retainer 1
4 Rocker arm shaft 2
5 Intake rocker arm 1
6 Exhaust rocker arm 1
7 Camshaft assembly 1
dure.
5-12
CAMSHAFT
EAS23770
REMOVING THE ROCKER ARMS AND

CAMSHAFT
1. Loosen:
• Lock nut “1”
• Adjusting screw “2”
4. Remove:
• Camshaft assembly “1”
TIP
Screw 8 mm (0.31 in) bolt or slide hammer bolt
“2” into the threaded end of the camshaft, and
then pull out the camshaft assembly.
2. Remove:
• Camshaft retainer bolt “1” Slide hammer bolt
• Camshaft retainer “2” 90890-01085
YU-01083-2
3. Remove:
• Intake rocker arm shaft
• Exhaust rocker arm shaft
• Intake rocker arm EAS23840
• Exhaust rocker arm CHECKING THE CAMSHAFT

TIP 1. Check:
Remove the rocker arm shafts with the slide • Bearing
hammer bolt “1” and weight “2”. Damage/wear → Replace the camshaft as-
sembly.
2. Check:
Slide hammer bolt • Camshaft lobes
90890-01085
Blue discoloration/pitting/scratches → Re-
YU-01083-2 place the camshaft assembly.
Weight
90890-01084
YU-01083-3
5-13
CAMSHAFT
3. Measure:
• Camshaft lobe dimensions “A” and “B”
Out of specification → Replace the camshaft
assembly.
Camshaft lobe dimensions

Intake A
25.881–25.981 mm (1.0189–
1.0229 in)
Limit
25.781 mm (1.0150 in)
Intake B 5. Check:
21.195–21.295 mm (0.8344– • Camshaft oil passage
0.8384 in) Obstruction → Blow out with compressed air.
Limit
21.095 mm (0.8305 in)
Exhaust A
25.841–25.941 mm (1.0174–
1.0213 in)
Limit
25.741 mm (1.0134 in)
Exhaust B
21.050–21.150 mm (0.8287–
0.8327 in)
Limit
20.950 mm (0.8248 in)
EAS23880
CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
• Rocker arm
• Adjusting screw
2. Check:
• Rocker arm shaft
Blue discoloration/excessive wear/pit-
ting/scratches → Replace or check the lubri-
cation system.
3. Measure:
• Rocker arm inside diameter “a”
Out of specification → Replace.
Rocker arm inside diameter

10.000–10.015 mm (0.3937–
0.3943 in)
Limit
4. Measure: 10.030 mm (0.3949 in)
• Camshaft runout
Out of specification → Replace the camshaft
assembly.
Camshaft runout limit

0.015 mm (0.0006 in)
5-14
CAMSHAFT
Rocker arm inner surface
Molybdenum disulfide oil
Rocker arm shaft
2. Lubricate:
• Camshaft
4. Measure: Camshaft lobe surface
• Rocker arm shaft outside diameter “a” Molybdenum disulfide grease
Out of specification → Replace. Camshaft oil passage
Rocker arm shaft outside diame- Camshaft bearing
ter Engine oil
9.981–9.991 mm (0.3930–0.3933
in) 3. Install:
Limit • Camshaft assembly “1”
9.950 mm (0.3917 in) TIP
Screw 8 mm (0.31 in) bolt or slide hammer bolt
“2” into the threaded end of the camshaft, and
then install the camshaft assembly.
Slide hammer bolt

90890-01085
YU-01083-2
5. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
TIP
Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
arm inside diameter.
Out of specification → Replace the defective
part(s).
4. Install:
Rocker-arm-to-rocker-arm-shaft • Intake rocker arm “1”
clearance • Exhaust rocker arm “2”
0.009–0.034 mm (0.0004–0.0013 • Rocker arm shafts “3”
in)
Limit TIP
0.080 mm (0.0032 in) • Screw 8 mm (0.31 in) bolt or slide hammer bolt
“4” into the threaded end of the rocker arm
EAS24040 shafts, and then install the rocker arm shafts.
INSTALLING THE CAMSHAFT AND ROCKER • Make sure the rocker arm shafts (intake and
ARMS exhaust) are completely pushed into the cylin-
1. Lubricate: der head.
• Rocker arms
• Rocker arm shafts
5-15
CAMSHAFT
Slide hammer bolt

90890-01085
YU-01083-2
5. Install:
• Camshaft retainer “1”
• Camshaft retainer bolt “2”
Camshaft retainer bolt

12 Nm (1.2 m·kg, 8.7 ft·lb)
T.
R.
5-16
VALVES AND VALVE SPRINGS
EAS24270

Removing the valves and valve springs

Rocker arm/Camshaft assembly Refer to “CAMSHAFT” on page 5-12.
1 Valve cotter 4
2 Upper valve spring seat 2
3 Valve spring 2
4 Intake valve 1
5 Exhaust valve 1
6 Valve stem seal 2
7 Lower valve spring seat 2
8 Valve guide 2
dure.
5-17
EAS24280
REMOVING THE VALVES

valves and related components.
TIP
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check:
• Valve sealing
Leakage at the valve seat → Check the valve 3. Remove:
face, valve seat, and valve seat width. • Upper valve spring seat “1”
Refer to “CHECKING THE VALVE SEATS” • Valve spring “2”
on page 5-20. • Valve “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Valve stem seal “4”
a. Pour a clean solvent “a” into the intake and • Lower valve spring seat “5”
exhaust ports.
TIP
b. Check that the valves properly seal.
Identify the position of each part very carefully so
TIP
that it can be reinstalled in its original place.
There should be no leakage at the valve seat “1”.
EAS24290
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE VALVES AND VALVE
2. Remove: GUIDES
• Valve cotters “1” The following procedure applies to all of the
TIP valves and valve guides.
Remove the valve cotters by compressing the 1. Measure:
valve spring with the valve spring compressor • Valve-stem-to-valve-guide clearance
“2” and the valve spring compressor attachment Out of specification → Replace the valve
“3”. guide.
• Valve-stem-to-valve-guide clearance =
Valve spring compressor Valve guide inside diameter “a” -
90890-04019 Valve stem diameter “b”
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
5-18
b. Install a new valve guide with the valve guide

Valve-stem-to-valve-guide clear- installer “2” and valve guide remover “1”.
ance (intake)
0.010–0.037 mm (0.0004–0.0015
in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm (0.0039 in)
c. After installing the valve guide, bore the valve
guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
TIP
After replacing the valve guide, reface the valve
seat.
Valve guide remover (ø4.5)

90890-04116
Valve guide remover (4.5 mm)
2. Replace: YM-04116
• Valve guide Valve guide installer (ø4.5)
TIP 90890-04117
Valve guide installer (4.5 mm)
To ease valve guide removal and installation, YM-04117
and to maintain the correct fit, heat the cylinder Valve guide reamer (ø5)
head to 100 °C (212 °F) in an oven. 90890-04099
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Valve guide reamer (5.0 mm)
a. Remove the valve guide with the valve guide YM-04099
remover “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
5-19
5. Measure: 3. Measure:
• Valve margin thickness D “a” • Valve seat width C “a”
Out of specification → Replace the valve. Out of specification → Replace the cylinder
head.
Valve margin thickness D (intake)
0.70 mm (0.0276 in) Valve seat width C (intake)
Valve margin thickness D (ex- 0.90–1.10 mm (0.0354–0.0433 in)
haust) Limit
1.00 mm (0.0394 in) 1.60 mm (0.06 in)
Valve seat width C (exhaust)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
1.60 mm (0.06 in)
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
TIP
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• When installing a new valve, always replace a. Apply Mechanic’s blueing dye (Dykem) “b”
the valve guide. onto the valve face.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.010 mm (0.0004 in)
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
TIP
EAS24300
CHECKING THE VALVE SEATS Where the valve seat and valve face contacted
The following procedure applies to all of the one another, the blueing will have been re-
valves and valve seats. moved.
1. Eliminate: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Carbon deposits 4. Lap:
(from the valve face and valve seat) • Valve face
2. Check: • Valve seat
• Valve seat
Pitting/wear → Replace the cylinder head.
5-20
TIP e. Apply a fine lapping compound to the valve

After replacing the cylinder head or replacing the face and repeat the above steps.
valve and valve guide, the valve seat and valve f. After every lapping procedure, be sure to
face should be lapped. clean off all of the lapping compound from the
valve face and valve seat.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ g. Apply Mechanic’s blueing dye (Dykem) “b”
a. Apply a coarse lapping compound “a” to the
onto the valve face.
valve face.
ECA13790
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
h. Install the valve into the cylinder head.

i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
b. Apply molybdenum disulfide oil onto the and lap the valve seat.
valve stem.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Install the valve into the cylinder head. EAS24310
d. Turn the valve until the valve face and valve CHECKING THE VALVE SPRINGS
seat are evenly polished, then clean off all of The following procedure applies to all of the
the lapping compound. valve springs.
TIP 1. Measure:
For the best lapping results, lightly tap the valve • Valve spring free length “a”
seat while rotating the valve back and forth be- Out of specification → Replace the valve
tween your hands. spring.
Free length (intake)

35.44 mm (1.40 in)
Limit
33.67 mm (1.33 in)
Free length (exhaust)
35.44 mm (1.40 in)
Limit
33.67 mm (1.33 in)
5-21
2. Measure: EAS2BK1023
• Compressed valve spring force “a” INSTALLING THE VALVES

Out of specification → Replace the valve The following procedure applies to all of the
spring. valves and related components.
1. Deburr:
Installed compression spring • Valve stem end
force (intake) (with an oil stone)
146–168 N (14.89–17.13 kgf,
32.83–37.77 lbf)
Installed compression spring
force (exhaust)
146–168 N (14.89–17.13 kgf,
32.83–37.77 lbf)
Installed length (intake)
24.10 mm (0.95 in)
Installed length (exhaust)
24.10 mm (0.95 in)
2. Lubricate:
• Valve stem “1”
• Valve stem seal “2” New
(with the recommended lubricant)
b. Installed length
3. Measure:
• Valve spring tilt “a”
Out of specification → Replace the valve
spring.
Spring tilt (intake)

2.5°/1.5 mm (0.059 in) 3. Install:
Spring tilt (exhaust) • Lower valve spring seat “1”
2.5°/1.5 mm (0.059 in)
• Valve stem seal “2” New
• Valve “3”
• Valve spring “4”
• Upper valve spring seat “5”
(into the cylinder head)
5-22
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up the smaller pitch “b” facing down.
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
a. Large pitch
b. Smaller pitch
4. Install:
• Valve cotters “1”
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
“2” and the valve spring compressor attachment
“3”.
Valve spring compressor

90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
5-23
CYLINDER AND PISTON
EAS24350
CYLINDER AND PISTON

Removing the cylinder and piston
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.R
.

1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Piston pin clip 2
5 Piston pin 1
6 Piston 1
7 Piston ring set 1
dure.
5-24
CYLINDER AND PISTON
EAS2BK1024
REMOVING THE CYLINDER AND PISTON

1. Remove:
• Cylinder
TIP
When removing the cylinder, remove the rear
shock absorber lower bolt first and then lift up
the back of the vehicle so that the cylinder does
not touch the frame.
2. Remove:
• Piston pin clips “1” 3. Remove:
• Piston pin “2” • Top ring
• Piston “3” • 2nd ring
ECA13810
• Oil ring
NOTICE
TIP
Do not use a hammer to drive the piston pin When removing a piston ring, open the end gap
out. with your fingers and lift the other side of the ring
TIP over the piston crown.
• Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.
• Before removing the piston pin, deburr the pis-
ton pin clip’s groove and the piston pin bore ar-
ea. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “4”.
Piston pin puller set EAS24400
90890-01304 CHECKING THE CYLINDER AND PISTON

Piston pin puller 1. Check:
YU-01304 • Piston wall
• Cylinder wall
Vertical scratches → Replace the cylinder,
and replace the piston and piston rings as a
set.
2. Measure:
• Piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
a. 45.0 mm (1.77 in) from the top of the cylinder
5-25
CYLINDER AND PISTON
TIP f. If out of specification, replace the cylinder,

Measure cylinder bore “C” by taking side-to-side and replace the piston and piston rings as a
and front-to-back measurements of the cylinder. set.
Then, find the average of the measurements. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
“C” = (X+Y)/2 EAS24430
CHECKING THE PISTON RINGS

1. Measure:
Cylinder
Bore • Piston ring side clearance
51.500–51.510 mm (2.0276– Out of specification → Replace the piston
2.0279 in) and piston rings as a set.
Wear limit TIP
51.610 mm (2.0319 in) Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
b. If out of specification, replace the cylinder, ring grooves and piston rings.
and replace the piston and piston rings as a
set.
c. Measure piston skirt diameter D “a” with the Piston ring
Top ring
micrometer.
Ring side clearance
0.020–0.080 mm (0.0008–
0.0032 in)
Limit
0.130 mm (0.0051 in)
2nd ring
Ring side clearance
0.020–0.060 mm (0.0008–
0.0024 in)
Limit
0.120 mm (0.0047 in)
b. 5.0 mm (0.20 in) from the bottom edge of the
piston
Piston
Diameter D
51.465–51.480 mm (2.0262–
2.0268 in)
d. If out of specification, replace the piston and

piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula. 2. Install:
• Piston ring
• Piston-to-cylinder clearance =
Cylinder bore “C” - (into the cylinder)
Piston skirt diameter “D” TIP
Level the piston ring into the cylinder with the
piston crown.
Piston-to-cylinder clearance
0.020–0.045 mm (0.0008–0.0018
in)
Limit
0.15 mm (0.0059 in)
5-26
CYLINDER AND PISTON
a. 45.0 mm (1.77 in) 3. Measure:

• Piston pin bore diameter “b”
3. Measure: Out of specification → Replace the piston.
• Piston ring end gap
Out of specification → Replace the piston Piston pin bore inside diameter
ring. 13.002–13.013 mm (0.5119–
TIP 0.5123 in)
The oil ring expander spacer end gap cannot be Limit
13.043 mm (0.5135 in)
measured. If the oil ring rail gap is excessive, re-
place all three piston rings.
Piston ring
Top ring
End gap (installed)
0.10–0.20 mm (0.0039–0.0079
in)
Limit
0.45 mm (0.0177 in)
2nd ring
End gap (installed)
0.20–0.30 mm (0.0079–0.0118 4. Calculate:
in) • Piston-pin-to-piston-pin-bore clearance
Limit Out of specification → Replace the piston pin
0.65 mm (0.0256 in) and piston as a set.
Oil ring • Piston-pin-to-piston-pin-bore clearance =
End gap (installed) Piston pin bore diameter “b” -
0.20–0.70 mm (0.0079–0.0276 Piston pin outside diameter “a”
in)
EAS24440 Piston-pin-to-piston-pin-bore
CHECKING THE PISTON PIN clearance
1. Check: 0.002–0.017 mm (0.0001–0.0007
• Piston pin in)
Blue discoloration/grooves → Replace the Limit
piston pin and then check the lubrication sys- 0.067 mm (0.0026 in)
tem.
2. Measure: EAS2BK1037
CHECKING THE TIMING CHAIN GUIDE

• Piston pin outside diameter “a”
1. Check:
Out of specification → Replace the piston pin.
• Timing chain guide (exhaust side)
Piston pin outside diameter Damage/wear → Replace.
12.996–13.000 mm (0.5117– EAS24450
0.5118 in) INSTALLING THE PISTON AND CYLINDER
Limit 1. Install:
12.976 mm (0.5109 in) • Lower oil ring rail “1”
5-27
CYLINDER AND PISTON
• Oil ring expander “2”

• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
TIP
Be sure to install the piston rings so that the
manufacturer marks or numbers face up.
a. Top ring
b. 2nd ring
c. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail
f. 20 mm (0.79 in)
A. exhaust side
2. Install: 5. Install:
• Piston “1” • Dowel pins
• Piston pin “2” • Cylinder head gasket New
• Piston pin clips “3” New • Cylinder “1”
TIP • Cylinder bolt
• Apply engine oil the piston pin. Cylinder bolt
• Make sure the arrow mark “a” on the piston 12 Nm (1.2 m·kg, 8.7 ft·lb)
T.
R.
points towards the exhaust side of the cylinder.

• Before installing the piston pin clip, cover the TIP
crankcase opening with a clean rag to prevent
• While compressing the piston rings with one
the clip from falling into the crankcase.
hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
• When installing the cylinder, remove the rear
shock absorber lower bolt first and then lift up
the back of the vehicle so that the cylinder
head does not touch the frame.
3. Lubricate:
• Piston
• Piston rings
• Cylinder
Engine oil
4. Offset:
• Piston ring end gaps
5-28
AC MAGNETO ROTOR
EAS2BK1025
AC MAGNETO ROTOR
Removing the AC magneto rotor and stator coil assembly
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.
69 Nm (6.9 m • kg, 50 ft • Ib)

T.R
.

Seat/Storage compartment/Right footboard side Refer to “GENERAL CHASSIS” on page
cover 4-1.
Spark plug cap/Air shroud (right side) Refer to “CYLINDER HEAD” on page 5-5.
1 Fan 1
2 AC magneto rotor 1
3 Woodruff key 1
4 Stator coil assembly coupler 2 Disconnect.
5 Stator coil assembly 1
dure.
5-29
AC MAGNETO ROTOR
EAS2BK1026 EAS2BK1027
REMOVING THE AC MAGNETO ROTOR INSTALLING THE AC MAGNETO ROTOR

1. Remove: 1. Install:
• Fan • Pickup coil
• AC magneto rotor nut “1” • Stator coil
• Spring washer
• Washer Pickup coil bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
TIP
R.
Stator coil screw
While holding the AC magneto rotor “2” with the 7 Nm (0.7 m·kg, 5.1 ft·lb)
rotor holding tool “3”, loosen the AC magneto ro-
tor nut. 2. Install:
• Woodruff key
Rotor holding tool • AC magneto rotor
90890-01235 • Washer
Universal magneto & rotor holder • Spring washer
YU-01235 • AC magneto rotor nut
TIP
• Clean the tapered portion of the crankshaft and
the AC magneto rotor hub.
• When installing the rotor, make sure the woo-
druff key is properly seated in the keyway of
the crankshaft.
3. Tighten:
• AC magneto rotor nut “1”
AC magneto rotor nut

2. Remove: 69 Nm (6.9 m·kg, 50 ft·lb)
T.
R.
• AC magneto rotor “1”

• Woodruff key TIP
TIP While holding the AC magneto rotor “2” with the
rotor holding tool “3”, tighten the AC magneto ro-
Remove the rotor using flywheel puller “2”
tor nut.
Flywheel puller
90890-01189 Rotor holding tool
YM-01189 90890-01235
YU-01235
3. Remove:
• Stator coil 4. Install:
• Pickup coil • Fan
Fan screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
5-30
KICKSTARTER
EAS2BK1028
KICKSTARTER
Removing the V-belt case cover
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.R
.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.R
.
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.R
.
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.R
.

Air filter case 4-1.
1 V-belt case air duct clamp screw 1 Loosen.
2 V-belt case air duct 1
3 V-belt case air filter element guide 1
4 V-belt case air filter element 1
5 V-belt case cover 1
6 V-belt case cover plate 1
7 V-belt case cover plate gasket 1
dure.
5-31
KICKSTARTER
Removing the kickstarter
6
23 Nm (2.3 m • kg, 17 ft • Ib)
T.R
.
7
LS
2
M
3
5
4 New

1 Kickstarter pinion gear 1
2 Kickstarter pinion gear clip 1
3 Kickstarter pedal 1
4 Circlip 1
5 Washer 1
6 Kickstarter spring 1
7 Kickstarter shaft 1
8 Bushing 1
dure.
5-32
KICKSTARTER
EAS24860
CHECKING THE KICKSTARTER

1. Check:
• Kickstarter shaft
• Kickstarter pinion gear
2. Check: 2
• Kickstarter spring a 3
Damage/wear → Replace. b 1
3. Measure:
• Kickstarter pinion gear clip force
3. Install:
(with the spring gauge)
• V-belt case cover
Out of specification → Replace the kickstart-
er pinion gear clip. V-belt case cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
Kick clip friction force P
R.
0.70–2.00 N (0.07–0.20 kgf, 0.16–
TIP
0.45 lbf)
Tighten the V-belt case cover bolts in stages and
in a crisscross pattern.
4. Install:
• Kickstarter pedal “1”
Kickstarter pedal bolt

23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
TIP
Install the kickstarter pedal as shown.
EAS2BK1029 1
INSTALLING THE KICKSTARTER
1. Install:
• Bushing
• Kickstarter spring
• Kickstarter shaft “1”
• Washer
• Circlip New
TIP
Install the kickstarter spring straight end on the
kickstarter shaft notch “a” and hook the spring
hooked end on the projection “b” as shown.
2. Install:
• Kickstarter pinion gear clip “2”
• Kickstarter pinion gear “3”
5-33
V-BELT AUTOMATIC TRANSMISSION
EAS24610

Removing the primary sheave and secondary sheave
60 Nm (6.0 m • kg, 43 ft • Ib)
T.R
.
54 Nm (5.4 m • kg, 39 ft • Ib)

T.R
.

V-belt case cover Refer to “KICKSTARTER” on page 5-31.
1 Kickstarter one-way clutch 1
2 Primary fixed sheave 1
3 Clutch housing 1
4 Secondary sheave assembly 1
5 V-belt 1
6 Spacer 1
7 Primary sliding sheave 1
8 Cam 1
9 Slider 3
10 Primary sheave weight 6
11 V-belt case cover gasket 1
dure.
5-34
Disassembling the secondary sheave

5
4
3
6
7 1
90 Nm (9.0 m • kg, 65 ft • Ib)
T.R
.
10 9
9
:Apply Shell dolium grease RJ ®

1 Nut 1
2 Clutch carrier assembly 1
3 Clutch shoe spring 3
5 Spring seat 1
6 Guide pin 3
7 Collar 3
8 Secondary sliding sheave 1
9 Oil seal 2
10 Secondary fixed sheave 1
cedure.
5-35
EAS24620 ECA13860
REMOVING THE PRIMARY SHEAVE NOTICE

1. Remove: Do not remove the secondary sheave nut at
• Primary sheave nut “1” this stage.
• Conical spring washer
• One-way clutch “2” TIP
• Primary fixed sheave “3” While holding the clutch carrier with the rotor
TIP holding tool “2”, loosen the secondary sheave
While holding the primary fixed sheave “3” with nut one full turn with the locknut wrench “3”.
the rotor holding tool “4”, loosen the primary
fixed sheave nut. Rotor holding tool
90890-01235
Rotor holding tool Universal magneto & rotor holder
90890-01235 YU-01235
Universal magneto & rotor holder Locknut wrench
YU-01235 90890-01348
YM-01348
EAS24630
3. Remove:
REMOVING THE SECONDARY SHEAVE
• Secondary sheave assembly “1”
1. Remove:
• V-belt “2”
• Clutch housing nut “1”
• Clutch housing “2” TIP
TIP Remove the V-belt and secondary sheave as-
sembly from the primary sheave side.
While holding the clutch housing with the sheave
holder “3”, loosen the clutch housing nut.
Sheave holder
90890-01701
YS-01880-A
EAS24640
DISASSEMBLING THE SECONDARY

SHEAVE
1. Remove:
• Secondary sheave nut “1”
2. Loosen:
5-36
TIP
Install the clutch spring holder “2” and clutch
spring holder arm “3” onto the secondary sheave
as shown. Then, compress the spring, and re-
move the secondary sheave nut “1”.
Clutch spring holder

90890-01337
Universal clutch compressor
holder
YM-33285 EAS24660
Clutch spring holder arm CHECKING THE CLUTCH SHOES

90890-01464 The following procedure applies to all of the
Compressor holder adapter clutch shoes.
YM-33285-6 1. Check:
• Clutch shoe
Damage/wear → Replace the clutch carrier
assembly.
Glazed areas → Sand with course sandpa-
per.
TIP
• After sanding the glazed areas, clean the
clutch with a cloth.
• Do not apply the grease or oil on the clutch
shoes.
2. Measure:
• Clutch shoe thickness “a”
Out of specification → Replace the clutch car-
rier assembly.
4. Spacer (Diameter = 40 mm [1.57 in]),

thickness 2–3 mm (0.08–0.12 in)
EAS24650
CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing Clutch shoe thickness
2.0 mm (0.08 in)
Limit
2. Measure: 1.0 mm (0.04 in)
• Clutch housing inside diameter “a”
Out of specification → Replace the clutch EAS24670
housing. CHECKING THE V-BELT

1. Check:
Clutch housing inside diameter • V-belt “1”
120.0–120.2 mm (4.724–4.732 in) Cracks/damage/wear → Replace.
Limit
Grease/oil → Clean the primary and second-
120.6 mm (4.748 in)
ary sheave.
5-37
2. Measure: 1. Check:
• V-belt width “a” • Primary sheave weight
Out of specification → Replace. Cracks/damage → Replace.
2. Measure:
V-belt width • Primary sheave weight outside diameter
21.6 mm (0.85 in) Out of specification → Replace.
Limit
19.4 mm (0.76 in) Weight outside diameter
19.9–20.1 mm (0.783–0.791 in)
Limit
19.5 mm (0.768 in)
EAS24680
CHECKING THE PRIMARY SHEAVE

1. Check:
• Primary sliding sheave “1”
EAS24700
• Primary fixed sheave “2” CHECKING THE SLIDERS
• Spacer “3” 1. Check:
Cracks/damage/wear → Replace the primary • Slider “1”
sliding sheave and primary fixed sheave as a Cracks/damage → Replace.
set.
EAS24710
CHECKING THE SECONDARY SHEAVE

1. Check:
• Secondary fixed sheave “1”
• Secondary sliding sheave “2”
Cracks/damage/wear → Replace the sec-
ondary fixed and sliding sheaves as a set.
EAS24690
CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedure applies to all of the pri-
mary sheave weights.
5-38
2. Check: 2. Install:
• Torque cam groove “1” • Primary sheave weights “1”
Damage/wear → Replace the secondary • Spacer “2”
fixed and sliding sheaves as a set.
3. Check:
• Guide pin “2”
• Collar
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
3. Install:
• Slider “1”
• Cam “2”
4. Check:
• Spring free length
Out of specification → Replace the spring.
Compression spring free length

94.3 mm (3.71 in)
Limit
89.6 mm (3.53 in) EAS24730
ASSEMBLING THE SECONDARY SHEAVE

1. Lubricate:
• Secondary fixed sheave inner surface “1”
• Secondary sliding sheave inner surface “2”
Shell dolium grease RJ®
EAS24720
ASSEMBLING THE PRIMARY SHEAVE

1. Clean:
• Primary fixed sheave “1”
• Primary sliding sheave “2”
• Spacer “3”
• Primary sheave weights “4”
• Cam
2. Install:
• Secondary sliding sheave “1”
TIP
Install the secondary sliding sheave onto the
secondary fixed sheave “2” with the oil seal
guide “3”.
5-39
TIP
Oil seal guide (ø41)
90890-01396 Attach the clutch spring holder “3” and clutch
spring holder arm “4” onto the secondary sheave
as shown. Then, compress the spring, and in-
stall the secondary sheave nut “2”.
Clutch spring holder

90890-01337
Universal clutch compressor
holder
YM-33285
Clutch spring holder arm
90890-01464
3. Install: Compressor holder adapter
• Collar YM-33285-6
• Guide pin “1”
4. Lubricate:
• Guide pin groove “2”
Shell dolium grease RJ®
5. Install:
• Spring seat “1”
TIP
Do not get any grease on the surfaces “a” and
“b” of the pulley. If any grease gets on the pulley,
be sure to wipe it off with alcohol, etc.
5. Spacer (Diameter = 40 mm [1.57 in]),
thickness 2–3 mm (0.08–0.12 in)
EAS24740
INSTALLING THE V-BELT

1. Install:
• Primary sliding sheave assembly
• V-belt “1”
• Secondary sheave assembly “2”
ECA2BK1015
NOTICE
6. Install: Do not allow grease to contact the V-belt or
• Compression spring secondary sheave assembly.
• Clutch carrier assembly “1” TIP
• Install the V-belt and secondary sheave as-
sembly onto the primary sheave side.
5-40
• Install the V-belt with the printed arrow mark on

the V-belt facing in the direction shown in the il- Sheave holder
lustration. 90890-01701
YS-01880-A
2. Tighten:
4. Position:
Secondary sheave nut • V-belt “1”
90 Nm (9.0 m·kg, 65 ft·lb) • Primary fixed sheave “2”
T.
R.
• One-way clutch “3”

TIP • Conical spring washer “4”
While holding the clutch carrier with the rotor • Primary sheave nut “5”
holding tool “2”, tighten the secondary sheave
nut with the locknut wrench “3”. Primary sheave nut
54 Nm (5.4 m·kg, 39 ft·lb)
T.
R.
Rotor holding tool

90890-01235 1
Universal magneto & rotor holder 2
3
YU-01235 4
Locknut wrench
90890-01348 5
YM-01348
TIP
• Install the V-belt onto the primary sheave “6”
(when the pulley is at its widest position) and
onto the secondary sheave assembly “7”
(when the pulley is at its narrowest position),
and make sure the V-belt is tight.
• While holding the primary fixed sheave with the
3. Install:
rotor holding tool “8”, tighten the primary
• Clutch housing “1”
sheave nut.
• Clutch housing nut “2”
Clutch housing nut Rotor holding tool

60 Nm (6.0 m·kg, 43 ft·lb) 90890-01235
T.
R.

TIP YU-01235
Tighten the clutch housing nut with the sheave
holder “3”.
5-41
5-42
STARTER CLUTCH
EAS24550
STARTER CLUTCH
Removing the starter clutch
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.R
.

Refer to “V-BELT AUTOMATIC TRANSMIS-
Primary sheave SION” on page 5-34.
1 Idle gear shaft holder 1
2 Starter clutch idle gear 1
3 Idle gear shaft 1
4 Starter clutch assembly 1
5 Starter wheel gear 1
6 Circlip 1
7 Bearing 1
dure.
5-43
STARTER CLUTCH
EAS2BK1030
b. When turning the starter wheel gear clock-
CHECKING THE STARTER CLUTCH
wise “A”, the starter clutch and the starter
1. Check:
wheel gear should turn freely. Otherwise the
• Starter clutch rollers “1”
starter clutch is faulty and must be replaced.
• Starter clutch spring caps “2”
c. When turning the starter wheel gear counter-
• Starter clutch springs “3”
clockwise “B”, it should engage. Otherwise
Damage/wear → Replace the starter clutch
the starter clutch is faulty and must be re-
assembly.
placed.
2. Check:
• Starter clutch idle gear “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Starter wheel gear “2” EAS2BK1031
Burrs/chips/roughness/wear → Replace. INSTALLING THE STARTER CLUTCH

1. Lubricate:
• Starter wheel gear
1 Molybdenum disulfide oil
2. Install:
• Starter wheel gear “1”
2 • Washer
• Starter clutch assembly “2”
3. Check:
TIP
• Starter wheel gear contacting surfaces
Damage/pitting/wear → Replace the starter Install the starter clutch assembly while turning
wheel gear. the starter wheel gear clockwise.
4. Check: 3. Lubricant:
• Starter clutch operation • Idle gear
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter wheel gear “1” onto the
starter clutch “2” and hold the starter clutch. Recommended lubricant
Idle gear surface of inside
5-44
STARTER CLUTCH
4. Install:
• Idle gear shaft
• Starter clutch idle gear
• Idle gear shaft holder
Idle gear shaft holder screw

6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
5-45
ELECTRIC STARTER
EAS2BK1032
ELECTRIC STARTER
Removing the starter motor
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.

Seat/Storage compartment 4-1.
1 Starter motor lead 1 Disconnect.
2 Engine ground lead 1 Disconnect.
3 Starter motor assembly 1
dure.
5-46
ELECTRIC STARTER
Disassembling the starter motor

1 Starter motor rear cover 1
2 Starter motor yoke 1
3 Armature assembly 1
4 Starter motor front cover 1
5 Brush set 1
cedure.
5-47
ELECTRIC STARTER
EAS24790
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances
1. Check: with the digital circuit tester.
• Commutator
Dirt → Clean with 600 grit sandpaper. Digital circuit tester
2. Measure: 90890-03174
• Commutator diameter “a” Model 88 Multimeter with ta-
Out of specification → Replace the starter chometer
motor. YU-A1927
Commutator diameter
22.0 mm (0.87 in) Armature coil
Limit Commutator resistance “1”
21.0 mm (0.83 in) 0.0306–0.0374 Ω (reference)
Insulation resistance “2”
Above 1 MΩ (reference)
2
1
1
3. Measure: 2
• Mica undercut “a”
Out of specification → Scrape the mica to the b. If any resistance is out of specification, re-
proper measurement with a hacksaw blade place the starter motor.
that has been grounded to fit the commutator.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Mica undercut (depth) 5. Measure:

1.50 mm (0.06 in) • Brush length “a”
Out of specification → Replace the brushes
TIP as a set.
The mica of the commutator must be undercut to
Brush overall length
ensure proper operation of the commutator. 10.0 mm (0.39 in)
Limit
3.50 mm (0.14 in)
4. Measure:
• Armature assembly resistances (commutator
and insulation)
6. Measure:
Out of specification → Replace the starter
motor. • Brush spring force
Out of specification → Replace the brush set.
5-48
ELECTRIC STARTER
Brush spring force

5.52–8.28 N (563–844 gf, 19.87–
29.80 oz)
7. Check:
• Bearing
• Oil seal
Damage/wear → Replace the front cover.
EAS24800
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor yoke “1”
• Starter motor front cover “2”
• Starter motor rear cover “3”
TIP
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the front and
rear covers.
EAS24810
INSTALLING THE STARTER MOTOR

1. Install:
• Starter motor
• Engine ground lead
• Starter motor bolts
Starter motor assembly bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
2. Connect:
• Starter motor lead
5-49
OIL PUMP
EAS24910
OIL PUMP
Removing the oil pump
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.R
.
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.R
.
4
3
5

Refer to “AC MAGNETO ROTOR” on page
Fan/AC magneto rotor/Stator coil assembly 5-29.
1 Oil pump cover 1
2 Gasket 1
3 Dowel pin 1
4 Oil pump assembly 1
5 Oil pump driven gear 1
6 Oil pump gasket 1
dure.
5-50
OIL PUMP
EAS24960
CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip

1. Check: clearance
• Oil pump drive gear Less than 0.150 mm (0.0059 in)
• Oil pump driven gear Limit
Cracks/damage/wear → Replace. 0.23 mm (0.0091 in)
• Oil pump housing Outer-rotor-to-oil-pump-housing
• Oil pump housing cover clearance
Cracks/damage/wear → Replace the oil 0.13–0.18 mm (0.0051–0.0071 in)
pump assembly. Limit
0.25 mm (0.0098 in)
2. Measure:
Oil-pump-housing-to-inner-and-
• Inner-rotor-to-outer-rotor-tip clearance “a” outer-rotor clearance
• Outer-rotor-to-oil-pump-housing clearance 0.06–0.10 mm (0.0024–0.0039 in)
“b” Limit
• Oil-pump-housing-to-inner-rotor-and-outer- 0.17 mm (0.0067 in)
rotor clearance “c”
Out of specification → Replace the oil pump 3. Check:
assembly. • Oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the oil pump assembly.
EAS25000
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Oil pump inner rotor
• Oil pump outer rotor
• Oil pump driven gear
1. Inner rotor
Engine oil
2. Outer rotor
2. Install:
3. Oil pump housing
• Oil pump outer rotor
• Oil pump inner rotor “1”
• Oil pump driven gear
• Pin “2”
TIP
When installing the oil pump inner rotor, align the
pin “2” in the oil pump shaft with the groove “a”
in the oil pump inner rotor “1”.
5-51
OIL PUMP
3. Install:
• Oil pump housing cover
4. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-51.
EAS2BK1033
INSTALLING THE OIL PUMP

1. Install:
• Oil pump assembly
Oil pump assembly screw

6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
ECA2BK1017
NOTICE
After tightening the screws, make sure the
oil pump turns smoothly.
5-52
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.R
.
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.R
.

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “CYLINDER AND PISTON” on page
Cylinder/piston 5-24.
Brake shoe Refer to “REAR BRAKE” on page 4-27.
V-belt automatic transmission SION” on page 5-34.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-46.
Starter clutch Refer to “STARTER CLUTCH” on page 5-43.
Refer to “AC MAGNETO ROTOR” on page
AC magneto rotor/stator coil assembly 5-29.
Oil pump Refer to “OIL PUMP” on page 5-50.
Transmission Refer to “TRANSMISSION” on page 5-60.
1 Timing chain guide (intake side) 1
2 Timing chain 1
3 Right crankcase 1
5-53
CRANKCASE
Separating the crankcase
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.R
.
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.R
.

4 Left crankcase 1
dure.
5-54
CRANKCASE
EAS25560 EAS2BK1035
DISASSEMBLING THE CRANKCASE CHECKING THE TIMING CHAIN AND CHAIN

1. Remove: GUIDE
• Crankcase bolts “1” 1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain, crankshaft and camshaft sprocket as a
set.
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
2. Check:
2. Remove: • Timing chain guide (intake side)
• Right crankcase “1” Damage/wear → Replace.
• Dowel pins
ECA13900 EAS25700
NOTICE ASSEMBLING THE CRANKCASE

Tap on one side of the crankcase with a soft- 1. Thoroughly clean all the gasket mating sur-
face hammer “2”. Tap only on reinforced faces and crankcase mating surfaces.
portions of the crankcase, not on the crank- 2. Apply:
case mating surfaces. Work slowly and care- • Sealant
fully and make sure the crankcase halves (onto the crankcase mating surfaces)
separate evenly.
Yamaha bond No. 1215
90890-85505
TIP
Do not allow any sealant to come into contact
with the oil gallery.
EAS25580
CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
• Crankcase 3. Install:
Cracks/damage → Replace. • Dowel pins
• Oil delivery passages • Right crankcase
Obstruction → Blow out with compressed air. 4. Tighten:
• Crankcase bolts “1”
5-55
CRANKCASE
TIP
Tighten the crankcase bolts in stages and in a
crisscross pattern.
Crankcase bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
T.
R.
5-56
CRANKSHAFT ASSEMBLY
EAS25970
CRANKSHAFT ASSEMBLY
Removing the crankshaft assembly

Separate.
Crankcase Refer to “CRANKCASE” on page 5-53.
1 Crankshaft assembly 1
dure.
5-57
CRANKSHAFT ASSEMBLY
EAS26000
REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:
• Crankshaft assembly “1”
• Timing chain “2”
TIP
• Before removing the crankshaft assembly, re-
move the timing chain from the crankshaft
sprocket.
• The crankshaft assembly cannot be removed if
the timing chain is attached onto the crankshaft 3. Measure:
sprocket. • Crankshaft width
Out of specification → Replace the crank-
shaft assembly.
Width A
44.80–44.85 mm (1.764–1.766 in)
EAS2BK1034
CHECKING THE CRANKSHAFT ASSEMBLY

1. Measure:
• Crankshaft runout
Out of specification → Replace the crank-
shaft assembly. 4. Check:
TIP • Crankshaft sprocket “1”
Turn the crankshaft slowly. Damage/wear → Replace the crankshaft as-
sembly.
Runout limit C • Bearing “2”
0.030 mm (0.0012 in) • Oil pump drive gear “3”
2. Measure: EAS26210
• Big end side clearance INSTALLING THE CRANKSHAFT
Out of specification → Replace the crank- ASSEMBLY
shaft assembly. 1. Install:
• Timing chain “1”
Big end side clearance D
0.10–0.30 mm (0.004–0.012 in)
Limit
1.0 mm (0.039 in)
5-58
CRANKSHAFT ASSEMBLY
TIP
When installing the timing chain, ensure that it
does not block the crankshaft journal opening
“a” of the left crankcase “2”.
2. Install:
• Crankshaft assembly “1”
TIP
Hold the timing chain with one hand while grasp-
ing the connecting rod at the top dead center
(T.D.C) with the other. Turn the crankshaft until
the timing chain and the timing chain gear tally.
5-59
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.R
.

Rear wheel Refer to “REAR WHEEL” on page 4-12.
Drain.
Transmission oil Refer to “CHANGING THE TRANSMISSION
OIL” on page 3-11.
Secondary sheave assembly SION” on page 5-34.
1 Transmission case cover 1
2 Gasket 1
3 Primary drive gear 1
4 Drive axle 1
5 Main axle assembly 1
dure.
5-60
TRANSMISSION
EAS26300
CHECKING THE TRANSMISSION

1. Measure:
• Main axle assembly runout
(With a centering device and dial gauge)
Out of specification → Replace the main axle
assembly.
Main axle runout limit

0.08 mm (0.0032 in)
5. Check:
• Transmission gear engagement
(each pinion gear to its respect wheel gear)
Incorrect → Reassemble the transmission
axle assemblies.
6. Check:
• Transmission gear movement
Rough movement → Replace the defective
2. Measure: part(s).
• Primary drive gear runout
Out of specification → Replace the primary
drive gear.
Primary drive gear runout limit

0.04 mm (0.0016 in)
3. Measure:
• Drive axle assembly runout
Out of specification → Replace the drive axle
assembly.
Drive axle runout limit

0.08 mm (0.0032 in)
4. Check:
• Transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
5-61
FUEL SYSTEM
FUEL TANK..................................................................................................... 6-1

CHECKING THE FUEL COCK..................................................................6-2
CHECKING THE FUEL COCK OPERATION............................................6-2
CARBURETOR................................................................................................6-3
CHECKING THE CARBURETOR ............................................................. 6-6
ASSEMBLING THE CARBURETOR.........................................................6-7
INSTALLING THE CARBURETOR ........................................................... 6-7
MEASURING AND ADJUSTING THE FUEL LEVEL ................................6-8
CHECKING THE AUTO CHOKE UNIT OPERATION ............................... 6-8
AIR INDUCTION SYSTEM (FOR AIR INDUCTION SYSTEM MODELS)..... 6-11

CHECKING THE AIR INDUCTION SYSTEM..........................................6-14
6
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
T.R
T.R
.
.
5 8
7
11
New
9 3
10
2
4
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.R
.

Seat/Storage compartment/Front cover/Left Refer to “GENERAL CHASSIS” on page
side cover 4-1.
1 Fuel tank cap 1
2 Filler cover 1
3 Fuel hose 1 Disconnect.
4 Fuel cock vacuum hose 1 Disconnect.
5 Fuel sender coupler 1 Disconnect.
6 Tail/brake light coupler 1 Disconnect.
7 Taillight assembly 1
8 Carrier stay 1
9 Fuel tank 1
10 Fuel cock 1
11 Fuel sender 1
dure.
6-1
FUEL TANK
EAS26650
CHECKING THE FUEL COCK

1. Check:
• Fuel cock
2. Check:
• Fuel cock strainer
Obstruction → Clean.
Blow out the jets with compressed air.
Damage → Replace.
EAS2BK1036
CHECKING THE FUEL COCK OPERATION

TIP
After installing the fuel cock, check its operation.
1. Check:
• Fuel cock operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the vacuum hose “1” and fuel
hose “2” from the carburetor.
b. Place a container under the end of the fuel
hose.
c. Connect a vacuum/pressure pump gauge set
“3” to the vacuum hose.
Vacuum/pressure pump gauge

set
90890-06756
YS-42423
d. Apply negative pressure and check that fuel

flows from the fuel hose.
e. Stop applying negative pressure and check
that the fuel stops flowing from the fuel hose.
3
2
f. If faulty, replace the fuel cock.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-2
CARBURETOR
EAS26720
CARBURETOR
Removing the carburetor
T.R
5 Nm (0.5 m • kg, 3.6 ft • Ib)
.
1
3

Seat/Storage compartment/Right footboard side Refer to “GENERAL CHASSIS” on page
cover 4-1.
1 Auto choke unit coupler 1 Disconnect.
2 Fuel hose 1 Disconnect.
3 Throttle cable assembly 1 Disconnect.
4 Intake manifold clamp screw 1 Loosen.
5 Air filter case joint clamp screw 1 Loosen.
6 Carburetor assembly 1
dure.
6-3
CARBURETOR
Disassembling the carburetor
6
4
7 5
9
10 8
11
LS
New
New
17
14 16
2
New
20
New 3
19
13 15 18
12
New

1 Auto choke unit 1
2 Starter block 1
3 Pilot screw set 1
4 Diaphragm cover 1
5 Piston valve spring 1
6 Jet needle set 1
7 Piston valve 1
8 Throttle stop screw set 1
9 Coasting enricher diaphragm cover 1
10 Spring 1
11 Coasting enricher diaphragm 1
12 Fuel drain screw 1
13 Float chamber 1
14 Accelerator valve 1
15 Float 1
16 Needle valve set 1
17 Pilot jet 1
6-4
CARBURETOR
Disassembling the carburetor
6
4
7 5
9
10 8
11
LS
New
New
17
14 16
2
New
20
New 3
19
13 15 18
12
New

18 Main jet 1
19 Main nozzle 1
20 Main needle 1
cedure.
6-5
CARBURETOR
EAS26770
CHECKING THE CARBURETOR

1. Check:
• Carburetor body 2
• Float chamber
2. Check: 1
• Fuel passages
Obstruction → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor 6. Check:
cleaning solution. • Piston valve “1”
b. Blow out all of the passages and jets with Damage/scratches/wear → Replace.
compressed air. • Piston valve diaphragm “2”
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Check:
3. Check:
• Diaphragm cover “1”
• Float chamber body
• Piston valve spring “2”
Dirt → Clean.
4. Check:
• Float “1”
• Float tang “2” 1
Damage → Replace.
1 2
2
8. Check:
• Coasting enricher diaphragm “1”
• Spring “2”
5. Check:
• Needle valve “1”
• Needle valve seat “2” 1
Damage/obstruction/wear → Replace the
needle valve and needle valve seat as a set.
6-6
C A R B U R E T O R
9. Check:
• Jet needle set “1” Pilot screw turns out
• Main jet “2” 2 (For air induction system
• Main nozzle “3” models)
1–7/8 (Except for air induction
• Main needle “4”
system models)
• Pilot jet “5”
• Pilot screw set “6”
Bends/wear/damage → Replace.
Blow out the jets with compressed air.
1 4
3 5
1
2
EAS26890
6 INSTALLING THE CARBURETOR

1. Install:
10.Check: • Carburetor
• Piston valve movement TIP
Insert the piston valve into the carburetor
Align the projection “a” on the carburetor with the
body and move it up and down.
slot “b” in the intake manifold.
Tightness → Replace the piston valve.
• Throttle valve movement
Sticks → Replace.
a
2. Install:
• Throttle cables
11.Check: 3. Adjust:
• Fuel hose • Engine idling speed
• Fuel overflow hose Refer to “ADJUSTING THE ENGINE IDLING
• Float chamber air vent hose SPEED” on page 3-5.
Obstruction → Clean. Engine idling speed
Blow out the hoses with compressed air. 1550–1750 r/min
EAS26810 4. Adjust:
ASSEMBLING THE CARBURETOR • Throttle cable free play
ECA14110
NOTICE
• Before assembling the carburetor, wash all
of the parts in a petroleum-based solvent. Throttle grip free play
• Always use a new gasket. 3.0–5.0 mm (0.12–0.20 in)
1. Install:
• Pilot screw “1”
6-7
CARBURETOR
EAS26910
MEASURING AND ADJUSTING THE FUEL

LEVEL 1
1. Measure:
• Fuel level “a”
Fuel level A (using fuel level

gauge)
6.6–7.6 mm (0.26–0.30 in) (be-
low the float chamber mating
surface) e. Install the carburetor assembly.
f. Measure the fuel level again.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ g. Repeat steps (a) to (f) until the fuel level is
a. Place the vehicle on a level surface. within specification.
b. Place the vehicle on the centerstand.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Install the fuel level gauge “1” onto the fuel
EAS26940
overflow pipe “2”.
CHECKING THE AUTO CHOKE UNIT
Fuel level gauge OPERATION
90890-01312 TIP
YM-01312-A When checking the auto choke unit, the ambient
temperature must be lower than 45 °C (113 °F).
d. Loosen the fuel drain screw “3”.
e. Hold the fuel level gauge vertically next to the 1. Remove:
line on the float chamber. • Carburetor
f. Start the engine. 2. Check:
g. Measure the fuel level. • Auto choke unit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a hose “1” to the starter air passage
1 “2” and blow into the hose.
TIP
a
When the starter plunger is open, air should
come out of the other side of the starter air pas-
sage.
3 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the carburetor assembly. 2
b. Check the needle valve seat and needle
1
valve.
c. If either is worn, replace the valve seat and b. If the starter plunger opens, perform step (3).
needle valve as a set. c. If the starter plunger closes, replace the auto
d. If both are fine, adjust the float level by slightly choke unit.
bending the float tang “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Auto choke unit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the auto choke unit leads to a 12.0 V
battery for five minutes.
6-8
CARBURETOR
• Positive battery lead “1”

yellow
• Negative battery lead “2”
yellow
b. Connect a hose “3” to the starter air passage

“4” and blow into the hose.
1
2
Y Y
4
3
c. If the starter plunger opens, replace the auto
choke unit.
d. If the starter plunger closes, the auto choke
unit is OK.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-9
CARBURETOR
6-10
AIR INDUCTION SYSTEM (FOR AIR INDUCTION SYSTEM MOD-
ELS)
EAS2BK2002
AIR INDUCTION SYSTEM (FOR AIR INDUCTION SYSTEM MODELS)
B
A
1 2 4 5
7
6
3
1 3
2
C
4 5 7
D
6
6-11
ELS)
1. Air induction system hose (to air filter case)
2. Air filter case
3. Air induction system hose (air filter case to
reed valve assembly)
4. Reed valve assembly
5. Air induction system vacuum hose (reed valve
assembly to intake manifold)
6. Air induction system hose (reed valve
assembly to air induction system pipe)
7. Air induction system pipe
A. Face the white paint mark on the air induction
system hose (to air filter case) inward.
B. Face the red paint mark on the air induction
system hose (air filter case to reed valve
assembly) inward.
C. Face the white paint mark on the air induction
system hose (air filter case to reed valve
assembly) outward.
D. Face the white paint mark on the air induction
system hose (reed valve assembly to air
induction system pipe) outward.
6-12
ELS)
Removing the reed valve assembly and hoses
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
.
1
7
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.R
.
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.R
.
6
2
3
4
New

Seat/Storage compartment/Front cover/Right Refer to “GENERAL CHASSIS” on page
side cover 4-1.
1 Air induction system hose (to air filter case) 1
Air induction system hose (air filter case to reed
2 1
valve assembly)
Air induction system hose (reed valve assembly
3 1
to air induction system pipe)
Air induction system vacuum hose (reed valve
4 1
assembly to intake manifold)
5 Air induction system pipe 1
6 Air filter case 1
7 Reed valve assembly 1
dure.
6-13
ELS)
EAS27060
2. Check:
CHECKING THE AIR INDUCTION SYSTEM
• Reed valve
• Reed valve stopper
Air induction
• Reed valve seat
The air induction system burns unburned ex-
Cracks/damage → Replace the reed valve
haust gases by injecting fresh air (secondary air)
assembly.
into the exhaust port, reducing the emission of
3. Check:
hydrocarbons. When there is negative pressure
• Air cut-off valve
at the exhaust port, the reed valve opens, allow-
Cracks/damage → Replace the reed valve
ing secondary air to flow into the exhaust port.
assembly.
The required temperature for burning the un-
4. Check:
burned exhaust gases is approximately 600 to
• Air cut-off valve operation
700 °C (1112 to 1292 °F).
Does not operate → Replace the reed valve
Air cut-off valve assembly.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
The air cut-off valve is operated by the intake a. Blow air through the end of the air induction
gas pressure through the piston valve dia- system hose (air filter case to reed valve as-
phragm. Normally, the air cut-off valve is open to sembly) and check that air flows from the
allow fresh air to flow into the exhaust port. Dur- reed valve assembly (to cylinder head side).
ing sudden deceleration (the throttle valve sud-
denly closes), negative pressure is generated Air cut-off valve opens
and the air cut-off valve is closed in order to pre- Perform step (b).
vent after-burning. Air cut-off valve closes
Additionally, at high engine speeds and when Replace the reed valve assembly.
the pressure decreases, the air cut-off valve au-
tomatically closes to guard against a loss of per-
formance due to self-EGR.
A
b. Install a vacuum/pressure pump to the reed

C
valve assembly “1” and apply negative pres-
A sure to the valve.
Vacuum/pressure pump gauge

set
90890-06756
B YS-42423
c. Blow air through the end of the air induction

C system hose (air filter case to reed valve as-
A. From the air filter case sembly) and check that air does not flow and
B. To the cylinder head out through the reed valve assembly (to cylin-
C. To the intake manifold der head side).
1. Check:
• Hoses
6-14
ELS)
Air cut-off valve opens
Replace the reed valve assembly.
Air cut-off valve closes
Air cut-off valve is OK.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-15
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 7-1

CIRCUIT DIAGRAM .................................................................................. 7-1
TROUBLESHOOTING ..............................................................................7-3
ELECTRIC STARTING SYSTEM .................................................................... 7-5

CIRCUIT DIAGRAM .................................................................................. 7-5
TROUBLESHOOTING ..............................................................................7-7
CHARGING SYSTEM......................................................................................7-9
CIRCUIT DIAGRAM .................................................................................. 7-9
TROUBLESHOOTING ............................................................................7-11
LIGHTING SYSTEM ......................................................................................7-13

CIRCUIT DIAGRAM ................................................................................ 7-13
SIGNALING SYSTEM ...................................................................................7-17

CIRCUIT DIAGRAM (FOR AIR INDUCTION SYSTEM MODELS) .........7-17
CIRCUIT DIAGRAM
(EXCEPT FOR AIR INDUCTION SYSTEM MODELS) .......................... 7-19
AUTO CHOKE SYSTEM ............................................................................... 7-25

CIRCUIT DIAGRAM (FOR AIR INDUCTION SYSTEM MODELS) .........7-25
CIRCUIT DIAGRAM
(EXCEPT FOR AIR INDUCTION SYSTEM MODELS) .......................... 7-27
SELF-DIAGNOSIS (FOR AIR INDUCTION SYSTEM MODELS) ...........7-30
ELECTRICAL COMPONENTS...................................................................... 7-31

CHECKING THE SWITCHES .................................................................7-33
CHECKING THE BULBS AND BULB SOCKETS ................................... 7-37
CHECKING THE FUSES ........................................................................7-38
CHECKING AND CHARGING THE BATTERY....................................... 7-38
7
CHECKING THE RELAYS ...................................................................... 7-41
CHECKING THE SPARK PLUG CAP .....................................................7-42
CHECKING THE IGNITION COIL ........................................................... 7-42
CHECKING THE STARTER MOTOR OPERATION ...............................7-43
CHECKING THE PICKUP COIL..............................................................7-44
CHECKING THE FUEL SENDER ........................................................... 7-44
CHECKING THE STATOR COIL ............................................................ 7-44
CHECKING THE RECTIFIER/REGULATOR ..........................................7-45
CHECKING THE HORN..........................................................................7-45
CHECKING THE AIR TEMPERATURE SENSOR
(FOR AIR INDUCTION SYSTEM MODELS)..........................................7-46
EAS27100
EAS27090
1 Br W/R G/W B
Y/R G/R W/L O
LOCK
OFF (BLACK)
ON 7 8
R W W 12
W W W/R W/R O
W W W/L W/L
B G/R G/W
Br R W W O
W W W W G/R
R W
R W W W/R W/L W/L W/R
(BLACK)
14
Y/R Br B B
CIRCUIT DIAGRAM
2
L/W 11 15
G/Y
L/W
IGNITION SYSTEM
Y/R
L/W
9 L/W
13 Y
3 R/W
R 10 W/R
R R L/W Br Br L/W
R OFF
B L L B
ON Y/R Y
L/B L/B B Y
4 R
5 (BLACK) (BLACK) Y
B Br L L/B
B
R/W
B R G/Y
B R
Br Br Br
B
B
36 17 16
7-1
Br/W Br Br Br Br
Br Br G/Y G/Y G/Y G/Y
37
P Ch L/B
L Br
Br/W P
Dg Ch Br/W G/Y G/Y
Dg B
B G
32 L/B P Br/W (BLACK)
(RED) Br L
L L Ch
26 33 34 35
Br L P Br/W
Ch Dg B Dg
G B
(BLACK)
(RED)
28 28
29 Y Y
30 31 Y
Y G B Ch Dg
27 Y
G Dg Ch B
G/W
G
25
L G/Y
G
B
B Y G B L
Ch Dg Dg Ch L G/Y Dg Ch
(GREEN)
22 21 Y
B Y L
G
24 23 B
B G 20 19 18
Ch Ch Dg Dg Ch Dg
(GREEN) Y B
B B B B
(BLACK)
L B
(BROWN) (BROWN) (GREEN) (GREEN)
B B B B
B L
IGNITION SYSTEM
IGNITION SYSTEM
1. Main switch
2. Main fuse
3. Wire lead
4. Battery
8. AC magneto
12.CDI unit
14.Ignition coil
15.Spark plug
7-2
IGNITION SYSTEM
EAS27130
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
Before troubleshooting, remove the following part(s):
1. Storage compartment
2. Left side cover
3. Right side cover
4. Front upper cowling
5. Battery cover
1. Check the fuse. NG →

(Main fuse)
Replace the fuse.
Refer to “CHECKING THE FUS-
ES” on page 7-38.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 7-38.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-7.
OK ↓
4. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 7-42.
OK ↓
5. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 7-42.
OK ↓
6. Check the pickup coil. NG →
Refer to “CHECKING THE PICKUP Replace the stator/pickup coil.
COIL” on page 7-44.
OK ↓
7. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-33.
OK ↓
7-3
IGNITION SYSTEM
8. Check the entire ignition system’s NG →

wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
page 7-1.
OK ↓
Replace the CDI unit.
7-4
EAS27170
EAS27160
1 Br W/R G/W B
Y/R G/R W/L O
LOCK
OFF (BLACK)
ON 7 8
R W W 12
W W W/R W/R O
W W W/L W/L
B G/R G/W
Br R W W O
W W W W G/R
R W
(BLACK)
14
Y/R Br B B
CIRCUIT DIAGRAM
2
L/W 11 15
G/Y
L/W
Y/R
L/W
9 L/W
13 Y
3 R/W
R 10 W/R
R R L/W Br Br L/W
R OFF
B L L B
ON Y/R Y
L/B L/B B Y
4 R
5 (BLACK) (BLACK) Y
B Br L L/B
B
R/W
B R G/Y
B R
6
ELECTRIC STARTING SYSTEM
Br Br Br
B
B
36 17 16
7-5
Br/W Br Br Br Br
37
P Ch L/B
L Br
Br/W P
Dg Ch Br/W G/Y G/Y
Dg B
B G
(RED) Br L
L L Ch
26 33 34 35
Br L P Br/W
Ch Dg B Dg
G B
(BLACK)
(RED)
28 28
29 Y Y
30 31 Y
Y G B Ch Dg
27 Y
G Dg Ch B
G/W
G
25
L G/Y
G
B
B Y G B L
(GREEN)
22 21 Y
B Y L
G
24 23 B
B G 20 19 18
Ch Ch Dg Dg Ch Dg
(GREEN) Y B
B B B B
(BLACK)
L B
B B B B
B L
1. Main switch
2. Main fuse
3. Wire lead
4. Battery
5. Starter relay
6. Starter motor
9. Right handlebar switch
10.Start switch
16.Front brake light switch
17.Rear brake light switch
7-6
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
TIP
2. Left side cover
3. Right side cover
4. Front handlebar cover
6. Battery cover

(Main fuse)
Replace the fuse.
ES” on page 7-38.
OK ↓
page 7-38.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step 5.
7-43.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-48.
OK ↓
5. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 7-41.
OK ↓
OK ↓
7. Check the brake light switch. NG →
(front/rear)
Replace the brake light switch.
Refer to “CHECKING THE
OK ↓
7-7
8. Check the start switch. NG →

Refer to “CHECKING THE Replace the right handlebar switch.
OK ↓
9. Check the entire starting system’s NG →
wiring. Properly connect or repair the starting sys-
page 7-5.
OK ↓
The starting system circuit is OK.
7-8
EAS27210
EAS27200
1 Br W/R G/W B
Y/R G/R W/L O
LOCK
OFF (BLACK)
ON 7 8
R W W 12
W W W/R W/R O
W W W/L W/L
B G/R G/W
Br R W W O
W W W W G/R
R W
(BLACK)
14
Y/R Br B B
CIRCUIT DIAGRAM
2
L/W 11 15
G/Y
L/W
Y/R
L/W
9 L/W
13 Y
3 R/W
CHARGING SYSTEM
R 10 W/R
R R L/W Br Br L/W
R OFF
B L L B
ON Y/R Y
L/B L/B B Y
4 R
5 (BLACK) (BLACK) Y
B Br L L/B
B
R/W
B R G/Y
B R
Br Br Br
B
B
36 17 16
7-9
Br/W Br Br Br Br
37
P Ch L/B
L Br
Br/W P
Dg Ch Br/W G/Y G/Y
Dg B
B G
(RED) Br L
L L Ch
26 33 34 35
Br L P Br/W
Ch Dg B Dg
G B
(BLACK)
(RED)
28 28
29 Y Y
30 31 Y
Y G B Ch Dg
27 Y
G Dg Ch B
G/W
G
25
L G/Y
G
B
B Y G B L
(GREEN)
22 21 Y
B Y L
G
24 23 B
B G 20 19 18
Ch Ch Dg Dg Ch Dg
(GREEN) Y B
B B B B
(BLACK)
L B
B B B B
B L
CHARGING SYSTEM
CHARGING SYSTEM
2. Main fuse
3. Wire lead
4. Battery
8. AC magneto
7-10
CHARGING SYSTEM
EAS27220
TROUBLESHOOTING
The battery is not being charged.
TIP
3. Battery cover

(Main fuse)
Replace the fuse.
ES” on page 7-38.
OK ↓
page 7-38.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR Replace the stator/pickup coil.
COIL” on page 7-44.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 7-45.
OK ↓
5. Check the entire charging system’s NG →
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system’s wiring.
page 7-9.
OK ↓
This circuit is OK.
7-11
CHARGING SYSTEM
7-12
EAS27250
EAS27240
1 Br W/R G/W B
Y/R G/R W/L O
LOCK
OFF (BLACK)
ON 7 8
R W W 12
W W W/R W/R O
W W W/L W/L
B G/R G/W
Br R W W O
W W W W G/R
R W
(BLACK)
14
Y/R Br B B
CIRCUIT DIAGRAM
2
L/W 11 15
G/Y
L/W
Y/R
LIGHTING SYSTEM
L/W
9 L/W
13 Y
3 R/W
R 10 W/R
R R L/W Br Br L/W
R OFF
B L L B
ON Y/R Y
L/B L/B B Y
4 R
5 (BLACK) (BLACK) Y
B Br L L/B
B
R/W
B R G/Y
B R
Br Br Br
B
B
36 17 16
Br/W Br Br Br Br
7-13
37
P Ch L/B
L Br
Br/W P
Dg Ch Br/W G/Y G/Y
Dg B
B G
(RED) Br L
L L Ch
26 33 34 35
Br L P Br/W
Ch Dg B Dg
G B
(BLACK)
(RED)
28 28
29 Y Y
30 31 Y
Y G B Ch Dg
27 Y
G Dg Ch B
G/W
G
25
L G/Y
G
B
B Y G B L
(GREEN)
22 21 Y
B Y L
G
24 23 B
B G 20 19 18
Ch Ch Dg Dg Ch Dg
(GREEN) Y B
B B B B
(BLACK)
L B
B B B B
B L
LIGHTING SYSTEM
LIGHTING SYSTEM
1. Main switch
2. Main fuse
3. Wire lead
4. Battery
9. Right handlebar switch
18.Tail/brake light
23.Auxiliary light
24.Headlight
26.Meter assembly
28.Meter light
31.High beam indicator light
32.Left handlebar switch
33.Dimmer switch
7-14
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight or meter light.
TIP
3. Battery cover
1. Check the each bulbs and bulb NG →

sockets condition.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
7-37.
OK ↓
(Main fuse)
Replace the fuse.
ES” on page 7-38.
OK ↓
page 7-38.
OK ↓
OK ↓
5. Check the dimmer switch. NG →
Refer to “CHECKING THE Replace the left handlebar switch.
OK ↓
6. Check the entire lighting system’s NG →
wiring. Properly connect or repair the lighting sys-
page 7-13.
OK ↓
This circuit is OK.
7-15
LIGHTING SYSTEM
7-16
EAS27270
1 Br W/R G/W B
Y/R G/R W/L O
EAS2BK2003
LOCK
OFF (BLACK)
ON 7 8
R W W 12
W W W/R W/R O
W W W/L W/L
B G/R G/W
Br R W W O
W W W W G/R
R W
(BLACK)
14
Y/R Br B B
2
L/W 11 15
G/Y
L/W
Y/R
L/W
9 L/W
13 Y
3 R/W
SIGNALING SYSTEM
R 10 W/R
R R L/W Br Br L/W
R OFF
B L L B
ON Y/R Y
L/B L/B B Y
4 R
5 (BLACK) (BLACK) Y
B Br L L/B
B
R/W
B R G/Y
B R
Br Br Br
B
B
36 17 16
Br/W Br Br Br Br
7-17
37
P Ch L/B
L Br
Br/W P
Dg Ch Br/W G/Y G/Y
Dg B
B G
(RED) Br L
L L Ch
26 33 34 35
Br L P Br/W
Ch Dg B Dg
CIRCUIT DIAGRAM (FOR AIR INDUCTION SYSTEM MODELS)
G B
(BLACK)
(RED)
28 28
29 Y Y
30 31 Y
Y G B Ch Dg
27 Y
G Dg Ch B
G/W
G
25
L G/Y
G
B
B Y G B L
(GREEN)
22 21 Y
B Y L
G
24 23 B
B G 20 19 18
Ch Ch Dg Dg Ch Dg
(GREEN) Y B
B B B B
(BLACK)
L B
B B B B
B L
SIGNALING SYSTEM
SIGNALING SYSTEM
1. Main switch
2. Main fuse
3. Wire lead
4. Battery
18.Tail/brake light
19.Rear left turn signal light
20.Rear right turn signal light
21.Front right turn signal light
22.Front left turn signal light
25.Fuel sender
26.Meter assembly
27.Fuel level meter
29.Turn signal indicator light
34.Horn switch
35.Turn signal switch
36.Turn signal relay
37.Horn
7-18
Br B O
1 W/R W/L Y/R
LOCK 7 8 (B) EAS2BK2004

R W W
W W W/R W/R O
W W W/L W/L O
W W 12
B
R W
W W W W 14
(B)
W/R W/L W/L W/R B
Br R W W
Y/R Br B
15
R
9 L/W Y/R
2
10 Y
L/W
13 B
L/W Br Br L/W
G/Y
L/W B L L B 11
R 11
L/B L/B Y/R Y
5 L/W B Y
3 R/W (B) (B) Y
R
B Br L L/B
R R L L L L B B B B B
R
4 R
R/W G/Y
B R
B R
6 Br Br Br Br
11 36
Br Br
Br/W
B
Br Br 17 16
37
B
B Ch L/B
Br Br P
7-19
Br/W P Br Br
Br/W Br Br
Dg B G/Y G/Y
G/Y G/Y
32 L/B P Br/W (B)
26 Br L G/Y G/Y
L L Ch
33 34 35
P Br/W
L Br Br L G/Y
B Dg
Dg Ch Ch Dg
(B) 11
B G G B
(R) (R) Y Y G/Y
Y
28 28 29 30 31 G/Y
B
G
G/Y
27 Y G B Ch Dg
Y 11
B
G Dg Ch B G
11
CIRCUIT DIAGRAM (EXCEPT FOR AIR INDUCTION SYSTEM MODELS)
B
Ch Ch Ch Ch
B B
B
25
L G/Y
G G
B
B B
Ch B Dg B Dg Ch L G/Y Dg Ch
B B Dg Dg Dg Dg
(G) (G)
Y G B L Y
11 B 22 21 Y L
24 23 20 19 18 B
Ch Ch Dg Dg Ch Dg
11 G
B B B B
Y B L B
(Br) (Br) (G) (G)
B B B (B)
B B
B L
SIGNALING SYSTEM
SIGNALING SYSTEM
1. Main switch
2. Main fuse
3. Wire lead
4. Battery
11.Joint
18.Tail/brake light
19.Rear left turn signal light
20.Rear right turn signal light
21.Front right turn signal light
22.Front left turn signal light
25.Fuel sender
26.Meter assembly
27.Fuel level meter
29.Right turn signal indicator light
30.Left turn signal indicator light
34.Horn switch
35.Turn signal switch
36.Turn signal relay
37.Horn
7-20
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
• Any of the following fail to light: Brake light, turn signal light or an indicator light.
• The horn fails to sound.
• The fuel level meter fails to operate.
TIP
2. Left side cover
3. Right side cover
6. Battery cover

(Main fuse)
Replace the fuse.
ES” on page 7-38.
OK ↓
page 7-38.
OK ↓
OK ↓
4. Check the entire signaling system’s NG →
wiring.
Refer to “CIRCUIT DIAGRAM (FOR
AIR INDUCTION SYSTEM MOD- Properly connect or repair the signaling
ELS)” on page 7-17 and “CIRCUIT system’s wiring.
DIAGRAM (EXCEPT FOR AIR IN-
DUCTION SYSTEM MODELS)” on
page 7-19.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
Checking the signaling system

The horn fails to sound.
1. Check the horn switch. NG →
OK ↓
7-21
SIGNALING SYSTEM
2. Check the horn. NG →

Refer to “CHECKING THE HORN” Replace the horn.
on page 7-45.
OK ↓
wiring.
page 7-19.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.

1. Check the tail/brake light bulb and NG →
socket.
Replace the tail/brake light bulb, socket or
Refer to “CHECKING THE BULBS
both.
7-37.
OK ↓
2. Check the brake light switch. NG →
(front/rear)
Replace the brake light switch.
Refer to “CHECKING THE
OK ↓
wiring.
page 7-19.
OK ↓
This circuit is OK.
The turn signal light, turn signal indicator light or both fail to blink.
NG →
1. Check the turn signal indicator light
bulb(s) and socket(s).
Replace the turn signal indicator light
Refer to “CHECKING THE BULBS
bulb(s), socket(s) or both.
7-37.
OK ↓
7-22
SIGNALING SYSTEM
2. Check the turn signal switch. NG →

OK ↓
3. Check the turn signal relay. NG →
Refer to “CHECKING THE RE- Replace the turn signal relay.
LAYS” on page 7-41.
OK ↓
wiring.
page 7-19.
OK ↓
This circuit is OK.
The fuel level meter fails to operate.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel sender.
SENDER” on page 7-44.
OK ↓
wiring.
page 7-19.
OK ↓
Replace the meter assembly.
7-23
SIGNALING SYSTEM
7-24
EAS27520
1 Br W/R G/W B
Y/R G/R W/L O
EAS2BK2005
LOCK
OFF (BLACK)
ON 7 8
R W W 12
W W W/R W/R O
W W W/L W/L
B G/R G/W
Br R W W O
W W W W G/R
R W
(BLACK)
14
Y/R Br B B
2
L/W 11 15
G/Y
L/W
Y/R
L/W
9 L/W
13 Y
3 R/W
R 10 W/R
R R L/W Br Br L/W
R OFF
B L L B
ON Y/R Y
AUTO CHOKE SYSTEM
L/B L/B B Y
4 R
5 (BLACK) (BLACK) Y
B Br L L/B
B
R/W
B R G/Y
B R
Br Br Br
B
B
36 17 16
Br/W Br Br Br Br
7-25
37
P Ch L/B
L Br
Br/W P
Dg Ch Br/W G/Y G/Y
Dg B
B G
(RED) Br L
L L Ch
26 33 34 35
Br L P Br/W
Ch Dg B Dg
CIRCUIT DIAGRAM (FOR AIR INDUCTION SYSTEM MODELS)
G B
(BLACK)
(RED)
28 28
29 Y Y
30 31 Y
Y G B Ch Dg
27 Y
G Dg Ch B
G/W
G
25
L G/Y
G
B
B Y G B L
(GREEN)
22 21 Y
B Y L
G
24 23 B
B G 20 19 18
Ch Ch Dg Dg Ch Dg
(GREEN) Y B
B B B B
(BLACK)
L B
B B B B
B L
AUTO CHOKE SYSTEM
AUTO CHOKE SYSTEM
8. AC magneto
11.Air temperature sensor
12.CDI unit
13.Auto choke unit
7-26
Br B O
1 W/R W/L Y/R
LOCK 7 8 (B) EAS2BK2006

R W W
W W W/R W/R O
W W W/L W/L O
W W 12
B
R W
W W W W 14
(B)
W/R W/L W/L W/R B
Br R W W
Y/R Br B
15
R
9 L/W Y/R
2
10 Y
L/W
13 B
L/W Br Br L/W
G/Y
L/W B L L B 11
R 11
L/B L/B Y/R Y
5 L/W B Y
3 R/W (B) (B) Y
R
B Br L L/B
R
4 R
R/W G/Y
B R
B R
6 Br Br Br Br
11 36
Br Br
Br/W
B
Br Br 17 16
37
B
B Ch L/B
Br Br P
7-27
Br/W P Br Br
Br/W Br Br
Dg B G/Y G/Y
G/Y G/Y
32 L/B P Br/W (B)
26 Br L G/Y G/Y
L L Ch
33 34 35
P Br/W
L Br Br L G/Y
B Dg
Dg Ch Ch Dg
(B) 11
B G G B
(R) (R) Y Y G/Y
Y
28 28 29 30 31 G/Y
B
G
G/Y
27 Y G B Ch Dg
Y 11
B
G Dg Ch B G
11
CIRCUIT DIAGRAM (EXCEPT FOR AIR INDUCTION SYSTEM MODELS)
B
Ch Ch Ch Ch
B B
B
25
L G/Y
G G
B
B B
B B Dg Dg Dg Dg
(G) (G)
Y G B L Y
11 B 22 21 Y L
24 23 20 19 18 B
Ch Ch Dg Dg Ch Dg
11 G
B B B B
Y B L B
(Br) (Br) (G) (G)
B B B (B)
B B
B L
AUTO CHOKE SYSTEM
AUTO CHOKE SYSTEM
8. AC magneto
11.Joint
12.CDI unit
13.Auto choke unit
7-28
AUTO CHOKE SYSTEM
EAS27540
TROUBLESHOOTING
The auto choke system fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Check the air temperature sensor. NG →

(For air induction system models)
Refer to “CHECKING THE AIR
Replace the air temperature sensor.
TEMPERATURE SENSOR (FOR
AIR INDUCTION SYSTEM MOD-
ELS)” on page 7-46.
OK ↓
2. Check the auto choke unit. NG →
Refer to “CHECKING THE AUTO
Replace the auto choke unit.
CHOKE UNIT OPERATION” on
page 6-8.
OK ↓
3. Check the entire auto choke system NG →
wiring. Properly connect or repair the auto choke
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 7-9.
OK ↓
Replace the CDI unit.
7-29
AUTO CHOKE SYSTEM
EAS2BK2007
SELF-DIAGNOSIS (FOR AIR INDUCTION SYSTEM MODELS)

This model has a self-diagnosis function. If a problem is detected, the engine trouble warning light will
come on or flash.
1
1. Engine trouble warning light
Warning light indication

Item Condition When engine is When engine is Maintenance job
running stopped
Air temperature Disconnected or Remains on Flashing Refer to “CHECK-
sensor short-circuit (The main switch ING THE AIR
is turned to “ON”.) TEMPERATURE
SENSOR (FOR
AIR INDUCTION
SYSTEM MOD-
ELS)” on page
7-46.
7-30
ELECTRICAL COMPONENTS
EAS27970
A 4
5
12
11
10
A
10 6
B 8
7
9
7-31

2. Air temperature sensor
3. Main switch
4. Starter relay
5. Fuel sender
6. Stator/pickup coil
7. Ignition coil
8. Spark plug cap
9. Battery
10. CDI unit
11. Horn
A. For air induction system models
B. Except for air induction system models
7-32
EAS27980
CHECKING THE SWITCHES
L/B 3
1 2 Ch Br/W Dg 4 5
Y G P B L/W B
Br L/W L/W Br
Y Y L B B L
L/B L/B
G G
Br R 7 6
LOCK
OFF
ON
7-33
1. Dimmer switch
2. Horn switch
3. Turn signal switch
4. Front brake light switch
5. Start switch
6. Rear brake light switch
7. Main switch
7-34
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA14370
NOTICE
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
YU-03112-C
TIP
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The terminal connections for switches (e.g., main switch, start switch) are shown in an illustration sim-
ilar to the one.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row in the switch illustration.
TIP
“ ” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the re-
spective switch position).
7-35
The following example illustration shows that:

There is continuity between red and brown when the switch is set to “ON”.
7-36
EAS27990 EWA13320
CHECKING THE BULBS AND BULB WARNING

SOCKETS Since the headlight bulb gets extremely hot,
Check each bulb and bulb socket for damage or keep flammable products and your hands
wear, proper connections, and also for continuity away from the bulb until it has cooled down.
between the terminals. ECA14380
Damage/wear → Repair or replace the bulb, NOTICE
bulb socket or both.
Improperly connected → Properly connect. • Be sure to hold the socket firmly when re-
No continuity → Repair or replace the bulb, bulb moving the bulb. Never pull the lead, other-
socket or both. wise it may be pulled out of the terminal in
the coupler.
Types of bulbs • Avoid touching the glass part of the head-
The bulbs used on this vehicle are shown in the light bulb to keep it free from oil, otherwise
illustration. the transparency of the glass, the life of the
• Bulbs “A” and “B” are used for the headlights bulb, and the luminous flux will be adverse-
and usually use a bulb holder that must be de- ly affected. If the headlight bulb gets soiled,
tached before removing the bulb. The majority thoroughly it with a cloth moistened with al-
of these types of bulbs can be removed from cohol or lacquer thinner.
their respective socket by turning them coun- 2. Check:
terclockwise. • Bulb (for continuity)
• Bulbs “C” is used for turn signal and tail/brake (with the pocket tester)
lights and can be removed from the socket by No continuity → Replace.
pushing and turning the bulb counterclockwise.
• Bulbs “D” and “E” are used for meter and indi- Pocket tester
cator lights and can be removed from their re- 90890-03112
spective socket by carefully pulling them out. Analog pocket tester
YU-03112-C
A B TIP
Check each bulb for continuity in the same man-
ner as described in the bulb section; however,
note the following.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c. If either of the readings indicate no continuity,
C replace the bulb.
D E ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs

bulbs.
1. Remove:
• Bulb
7-37
Checking the condition of the bulb sockets 3. Replace:

The following procedure applies to all of the bulb • Blown fuse
sockets. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Check: a. Set the main switch to “OFF”.
• Bulb socket (for continuity) b. Install a new fuse of the correct amperage
(with the pocket tester) rating.
No continuity → Replace. c. Set on the switches to verify if the electrical
circuit is operational.
Pocket tester d. If the fuse immediately blows again, check
90890-03112 the electrical circuit.
YU-03112-C Amperage
Fuses Q’ty
rating
TIP Main 15 A 1
Check each bulb socket for continuity in the Spare 15 A 1
same manner as described in the bulb section;
EWA13310
however, note the following.
WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Never use a fuse with an amperage rating
a. Install a good bulb into the bulb socket.
other than that specified. Improvising or us-
b. Connect the pocket tester probes to the re-
ing a fuse with the wrong amperage rating
spective leads of the bulb socket.
may cause extensive damage to the electri-
c. Check the bulb socket for continuity. If any of
cal system, cause the lighting and ignition
the readings indicate no continuity, replace
systems to malfunction and could possibly
the bulb socket.
cause a fire.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28000
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE FUSES 4. Install:
The following procedure applies to all of the fus- • Battery cover
es. Refer to “GENERAL CHASSIS” on page 4-1.
ECA13680
NOTICE EAS28030
CHECKING AND CHARGING THE BATTERY

To avoid a short circuit, always set the main EWA13290
switch to “OFF” when checking or replacing WARNING

a fuse. Batteries generate explosive hydrogen gas
1. Remove: and contain electrolyte which is made of poi-
• Battery cover sonous and highly caustic sulfuric acid.
Refer to “GENERAL CHASSIS” on page 4-1. Therefore, always follow these preventive
2. Check: measures:
• Fuse • Wear protective eye gear when handling or
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ working near batteries.
a. Connect the pocket tester to the fuse and • Charge batteries in a well-ventilated area.
check the continuity. • Keep batteries away from fire, sparks or
TIP open flames (e.g., welding equipment,
Set the pocket tester selector to “Ω × 1”. lighted cigarettes).
• DO NOT SMOKE when charging or han-
Pocket tester dling batteries.
90890-03112 • KEEP BATTERIES AND ELECTROLYTE
Analog pocket tester OUT OF REACH OF CHILDREN.
YU-03112-C • Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
b. If the pocket tester indicates “∞”, replace the injury.
fuse. FIRST AID IN CASE OF BODILY CONTACT:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EXTERNAL
7-38
• Skin — Wash with water. 3. Remove:

• Eyes — Flush with water for 15 minutes and • Battery
get immediate medical attention. 4. Check:
INTERNAL • Battery terminal voltage
• Drink large quantities of water or milk fol- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
lowed with milk of magnesia, beaten egg or a. Connect a pocket tester to the battery termi-
vegetable oil. Get immediate medical atten- nals.
tion. • Positive tester probe →
ECA2BK1001 positive battery terminal
NOTICE • Negative tester probe →
negative battery terminal
• This is a VRLA (Valve Regulated Lead Acid)
battery. Never remove the sealing caps be- TIP
cause the balance between cells will not be
• The charge state of a VRLA (Valve Regulated
maintained and battery performance will
Lead Acid) battery can be checked by measur-
deteriorate.
ing its open-circuit voltage (i.e., the voltage
• Charging time, charging amperage and
when the positive battery terminal is discon-
charging voltage for a VRLA (Valve Regu-
nected).
lated Lead Acid) battery are different from
• No charging is necessary when the open-cir-
those of conventional batteries. The VRLA
cuit voltage equals or exceeds 12.8 V.
(Valve Regulated Lead Acid) battery should
be charged as explained in the charging b. Check the charge of the battery, as shown in
method illustrations. If the battery is over- the charts and the following example.
charged, the electrolyte level will drop con- Example
siderably. Therefore, take special care Open-circuit voltage = 12.0 V
when charging the battery. Charging time = 6.5 hours
Charge of the battery = 20–30%
TIP
Since VRLA (Valve Regulated Lead Acid) bat-
teries are sealed, it is not possible to check the
charge state of the battery by measuring the
specific gravity of the electrolyte. Therefore, the
A
charge of the battery has to be checked by mea-
suring the voltage at the battery terminals.
1. Remove:
• Battery cover
h
B
2. Disconnect:
• Battery leads A. Open-circuit voltage
(from the battery terminals) B. Charging time
ECA13640
NOTICE
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
7-39
• If the battery becomes hot to the touch at

C any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot
A batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of a VRLA (Valve Reg-
ulated Lead Acid) battery stabilizes about
30 minutes after charging has been com-
B pleted. Therefore, wait 30 minutes after
charging is completed before measuring
A. Open-circuit voltage the open-circuit voltage.
B. Charge of the battery
C. Temperature 20 °C (68 °F) D
C
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge:
• Battery
(refer to appropriate charging method) A
EWA13300
WARNING
Do not quick charge a battery.
ECA13670
B E
NOTICE
A. Open-circuit voltage
• Never remove the VRLA (Valve Regulated
B. Checking the open-circuit voltage
Lead Acid) battery sealing caps.
C. Temperature 20 °C (68 °F)
• Do not use a high-rate battery charger
D. Charge
since it forces a high-amperage current
E. Time (minutes)
into the battery quickly and can cause bat-
tery overheating and battery plate damage.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• If it is impossible to regulate the charging Charging method using a variable-current
current on the battery charger, be careful (voltage) charger
not to overcharge the battery. a. Measure the open-circuit voltage prior to
• When charging a battery, be sure to remove charging.
it from the vehicle. (If charging has to be
TIP
done with the battery mounted on the vehi-
cle, disconnect the negative battery lead Voltage should be measured 30 minutes after
from the battery terminal.) the engine is stopped.
• To reduce the chance of sparks, do not b. Connect a charged and AMP meter to the
plug in the battery charger until the battery battery and start charging.
charger leads are connected to the battery. TIP
• Before removing the battery charger lead
Set the charging voltage at 16–17 V. If the set-
clips from the battery terminals, be sure to
ting is lower, charging will be insufficient. If too
turn off the battery charger.
high, the battery will be over-charged.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and c. Make sure that the current is higher than the
that they are not shorted. A corroded bat- standard charging current written on the bat-
tery charger lead clip may generate heat in tery.
the contact area and a weak clip spring may TIP
cause sparks. If the current is lower than the standard charging
current written on the battery, set the charging
voltage adjust dial at 20–24 V and monitor the
amperage for 3–5 minutes to check the battery.
7-40
• Standard charging current is reached 12.8 V or more --- Charging is complete.

Battery is good. 12.7 V or less --- Recharging is required.
• Standard charging current is not reached Under 12.0 V --- Replace the battery.
Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Adjust the voltage so that the current is at the 6. Install:
standard charging level. • Battery
e. Set the time according to the charging time 7. Connect:
suitable for the open-circuit voltage. • Battery leads
Refer to “Battery condition checking steps”. (to the battery terminals)
f. If charging requires more than 5 hours, it is ECA13630
advisable to check the charging current after NOTICE

a lapse of 5 hours. If there is any change in First, connect the positive battery lead “1”,
the amperage, readjust the voltage to obtain and then the negative battery lead “2”.
the standard charging current.
g. Measure the battery open-circuit voltage after
1
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant volt- 8. Check:
age charger • Battery terminals
a. Measure the open-circuit voltage prior to Dirt → Clean with a wire brush.
charging. Loose connections → Connect properly.
TIP 9. Lubricate:
Voltage should be measured 30 minutes after • Battery terminals
the engine is stopped.
b. Connect a charger and AMP meter to the bat- Dielectric grease
tery and start charging.
c. Make sure that the current is higher than the 10.Install:
standard charging current written on the bat- • Battery cover
tery. Refer to “GENERAL CHASSIS” on page 4-1.
TIP
EAS28040
If the current is lower than the standard charging CHECKING THE RELAYS
current written on the battery, this type of battery Check each switch for continuity with the pocket
charger cannot charge the VRLA (Valve Regu- tester. If the continuity reading is incorrect, re-
lated Lead Acid) battery. A variable voltage place the relay.
charger is recommended.
Pocket tester
d. Charge the battery until the battery’s charg- 90890-03112
ing voltage is 15 V. Analog pocket tester
TIP YU-03112-C
Set the charging time at 20 hours (maximum).
1. Disconnect the relay from the wire harness.
e. Measure the battery open-circuit voltage after 2. Connect the pocket tester (Ω × 1) and battery
leaving the battery unused for more than 30 (12 V) to the relay terminal as shown.
minutes. Check the relay operation.
Rough movement → Replace.
7-41
Starter relay
Pocket tester
3 90890-03112
R
2 YU-03112-C
L/W L/W
R/W R/W
R
1
4
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
c. Measure the spark plug cap resistance.

Result
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Continuity → OK
No continuity → Replace. EAS28090
CHECKING THE IGNITION COIL

1. Check:
Turn signal relay • Primary coil resistance
Primary coil resistance

0.32–0.48 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
1. Positive battery lead b. Connect the pocket tester (Ω × 1) to the igni-
2. Negative battery lead tion coil as shown.
Result Pocket tester

Relay operate → OK 90890-03112
Relay do not operate → Re- Analog pocket tester
place. YU-03112-C
EAS28060 • Positive tester probe

CHECKING THE SPARK PLUG CAP Orange “1”
1. Check: • Negative tester probe
• Spark plug cap resistance Ignition coil base “2”
Resistance
10.0 k.Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark
plug lead.
b. Connect the pocket tester (Ω × 1 k) to the
spark plug cap as shown.
c. Measure the primary coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-42
2. Check:
• Secondary coil resistance
Secondary coil resistance

5.68–8.52 k.Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Ω × 1 k) to the ig-
nition coil as shown. 1. Ignition checker
2. Spark plug cap
Pocket tester
90890-03112 e. Crank the engine by pushing the starter
Analog pocket tester switch and gradually increase the spark gap
YU-03112-C until a misfire occurs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Positive tester probe EAS28940
Orange “1” CHECKING THE STARTER MOTOR
• Negative tester probe OPERATION
Spark plug lead “2”
1. Check:
• Starter motor operation
Does not operate → Perform the electric
starting system troubleshooting, starting with
step 4.
Refer to “TROUBLESHOOTING” on page
7-7.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive battery terminal “1” and
starter motor lead “2” with a jumper lead “3”.
EWA13810
WARNING
c. Measure the secondary coil resistance. • A wire that is used as a jumper lead must
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ have at least the same capacity of the bat-
3. Check: tery lead, otherwise the jumper lead may
• Ignition spark gap burn.
Out of specification → Replace. • This check is likely to produce sparks,
therefore, make sure no flammable gas or
Minimum ignition spark gap fluid is in the vicinity.
6.0 mm (0.24 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the spark
plug.
b. Connect the ignition checker/spark checker
“1” as shown.
Ignition checker
90890-06754
Oppama pet-4000 spark checker
YM-34487
b. Check the starter motor operation.
c. Turn the main switch to “ON”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Measure the ignition spark gap “a”.
7-43
EAS2BK1001
CHECKING THE PICKUP COIL Pocket tester

1. Disconnect: 90890-03112
• Pickup coil coupler Analog pocket tester
(from the wire harness) YU-03112-C
2. Check:
• Pickup coil resistance • Positive tester probe →
Out of specification → Replace the sta- Green “1”
tor/pickup coil. • Negative tester probe →
Black “2”
Pickup coil resistance
248–372 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
pickup coil coupler as shown.
Pocket tester
90890-03112 G B
YU-03112-C 1 2
• Positive tester probe b. Measure the fuel sender resistance.

White/Red “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Negative tester probe EAS28150
White/Blue “2” CHECKING THE STATOR COIL

1. Disconnect:
• Stator coil coupler
(from the wire harness)
2. Check:
• Stator coil resistance
Out of specification → Replace the sta-
tor/pickup coil.
b. Measure the pickup coil resistance. Stator coil resistance

0.480–0.720 Ω
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28230 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE FUEL SENDER a. Connect the pocket tester (Ω × 1) to the stator
1. Disconnect: coil coupler as shown.
• Fuel sender coupler
(from the wire harness) Pocket tester
2. Check: 90890-03112
• Fuel sender resistance Analog pocket tester
YU-03112-C
Sender unit resistance (full)
4.0–10.0 Ω • Positive tester probe
Sender unit resistance (empty) White “1”
90.0–100.0 Ω • Negative tester probe
White “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) to the fuel • Positive tester probe
sender terminal as shown. White “1”
• Negative tester probe
White “3”
7-44
• Positive tester probe

White “2”
White “3”
1 2 W R 1
W W
W W
W c. Start the engine and let it run at approximate-

ly 5000 r/min.
d. Measure the charging voltage.
3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28180
b. Measure the stator coil resistances. CHECKING THE HORN
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Check:
EAS28170 • Horn voltage
CHECKING THE RECTIFIER/REGULATOR Out of specification → Properly connect or re-
1. Check: pair the signaling system’s wiring.
• Charging voltage
Out of specification → Replace the rectifi- Horn voltage
er/regulator. 12 V
Rectifier/regulator output voltage ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

About 14 V at 5000 r/min a. Connect the pocket tester (20 V DC) to the
horn terminal.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the digital tachometer to the ignition coil Pocket tester
of cylinder. 90890-03112
b. Connect the digital circuit tester (20 V DC) to Analog pocket tester
the rectifier/regulator coupler as shown. YU-03112-C
Pocket tester • Positive tester probe

90890-03112 Brown “1”
Analog pocket tester • Negative tester probe
YU-03112-C Ground
Digital tachometer
90890-06760
YU-39951-B
1
• Positive tester probe
Red “1”
Ground
b. Turn the main switch to “ON”.

c. Measure the voltage (DC 12 V) of brown at
the horn coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-45
2. Check:
• Operation of the horn
k
The horn fails to sound → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the horn coupler at the horn.
b. Connect a jumper lead “1” to the brown termi-
nal in the horn coupler and the horn terminal.
c. Connect a jumper lead “1” to the horn termi-
nal and ground.
1 d. Slowly heat the water, and then let it cool

down to the specified temperature.
e. Check the air temperature sensor resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Air temperature sensor
d. Turn the main switch to “ON”.

e. Check that the horn does sound.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2BK2008
CHECKING THE AIR TEMPERATURE

SENSOR (FOR AIR INDUCTION SYSTEM
MODELS)
1. Remove:
• Air temperature sensor
2. Check:
• Air temperature sensor resistance
Air temperature sensor resis-

tance
12.12–13.98 kΩ at 20 °C (68 °F)
Air temperature sensor resis-
tance
1.63–1.87 kΩ at 80 °C (176 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1 k) to the air
temperature sensor terminals as shown.
Pocket tester
90890-03112
YU-03112-C
b. Immerse the air temperature sensor “1” in a

container filled with water “2”.
TIP
Make sure the air temperature sensor terminals
do not get wet.
c. Place a thermometer “3” in the water.
7-46
7-47
TROUBLESHOOTING
TROUBLESHOOTING.....................................................................................8-1
GENERAL INFORMATION ....................................................................... 8-1
STARTING FAILURE/HARD STARTING.................................................. 8-1
INCORRECT ENGINE IDLING SPEED .................................................... 8-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................... 8-2
FAULTY CLUTCH .....................................................................................8-2
OVERHEATING ........................................................................................8-2
POOR BRAKING PERFORMANCE.......................................................... 8-3
FAULTY FRONT FORK LEGS..................................................................8-3
UNSTABLE HANDLING ............................................................................8-3
FAULTY LIGHTING OR SIGNALING SYSTEM ........................................ 8-3
8
TROUBLESHOOTING
EAS28450
• Incorrect fuel level
TROUBLESHOOTING • Improperly adjusted pilot screw
EAS28460
3. Auto choke unit
GENERAL INFORMATION • Faulty starter plunger
TIP • Faulty auto choke unit
• Faulty CDI unit
The following guide for troubleshooting does not
cover all the possible causes of trouble. It should
Electrical system
be helpful, however, as a guide to basic trouble-
1. Battery
shooting. Refer to the relative procedure in this
• Discharged battery
manual for checks, adjustments, and replace-
• Faulty battery
ment of parts.
2. Fuse
• Blown, damaged or incorrect fuse
EAS28480
STARTING FAILURE/HARD STARTING • Improperly installed fuse

3. Spark plug
Engine • Incorrect spark plug gap
1. Cylinder and cylinder head • Incorrect spark plug heat range
• Loose spark plug • Fouled spark plug
• Loose cylinder head or cylinder • Worn or damaged electrode
• Damaged cylinder head gasket • Worn or damaged insulator
• Damaged cylinder gasket • Faulty spark plug cap
• Worn or damaged cylinder 4. Ignition coil
• Incorrect valve clearance • Cracked or broken ignition coil body
• Improperly sealed valve • Broken or shorted primary or secondary coils
• Incorrect valve-to-valve-seat contact • Faulty spark plug lead
• Incorrect valve timing 5. Ignition system
• Faulty valve spring • Faulty CDI unit
• Seized valve • Faulty pickup coil
2. Piston and piston ring • Broken AC magneto rotor woodruff key
• Improperly installed piston ring 6. Switches and wiring
• Damaged, worn or fatigued piston ring • Faulty main switch
• Seized piston ring • Broken or shorted wiring
• Seized or damaged piston • Faulty front, rear or both brake light switches
3. Air filter • Faulty start switch
• Improperly installed air filter • Improperly grounded circuit
• Clogged air filter element • Loose connections
4. Crankcase and crankshaft 7. Starting system
• Improperly assembled crankcase • Faulty starter motor
• Seized crankshaft • Faulty starter relay
• Faulty starter clutch
Fuel system EAS28500
1. Fuel Tank INCORRECT ENGINE IDLING SPEED
• Empty fuel tank
• Clogged fuel tank cap breather hole Engine
• Deteriorated or contaminated fuel 1. Cylinder and cylinder head
• Clogged or damaged fuel hose • Incorrect valve clearance
2. Carburetor • Damaged valve train components
• Deteriorated or contaminated fuel 2. Air filter
• Clogged pilot jet • Clogged air filter element
• Clogged pilot air passage
• Sucked-in air Fuel system
• Damaged float 1. Carburetor
• Worn needle valve • Loose or clogged pilot jet
8-1
TROUBLESHOOTING
• Damaged or loose carburetor joint 3. Clutch spring(s)

• Improperly adjusted engine idling speed • Damaged clutch spring
(throttle stop screw) 4. Transmission gear(s)
• Improper throttle cable free play • Damaged transmission gear
• Flooded carburetor
2. Auto choke unit Clutch slips
• Faulty starter plunger 1. Clutch shoe spring(s)
• Faulty CDI unit • Damaged, loose or worn clutch shoe spring
2. Clutch shoe(s)
Electrical system • Damaged or worn clutch shoe
1. Battery 3. Primary sliding sheave
• Discharged battery • Seized primary sliding sheave
• Faulty battery
2. Spark plug Poor starting performance
• Incorrect spark plug gap 1. V-belt
• Incorrect spark plug heat range • Slipping V-belt
• Fouled spark plug • Oil or grease on the V-belt
• Worn or damaged electrode 2. Primary sliding sheave
• Worn or damaged insulator • Faulty operation
• Faulty spark plug cap • Worn primary sliding sheave
3. Ignition coil 3. Secondary sliding sheave
• Broken or shorted primary or secondary coils • Incorrect
• Faulty spark plug lead • Worn pin groove
4. Ignition system • Worn pin
• Faulty CDI unit 4. Clutch shoe(s)
• Faulty pickup coil • Bent, damaged or worn clutch shoe
• Broken AC magneto rotor woodruff key
Poor speed performance
EAS28520
1. V-belt
POOR MEDIUM-AND-HIGH-SPEED
• Oil or grease on the V-belt
PERFORMANCE
2. Primary sheave weight(s)
Refer to “STARTING FAILURE/HARD START-
• Faulty operation
ING” on page 8-1.
• Worn primary sheave weight(s)
Engine 3. Primary fixed sheave
1. Air filter • Worn primary fixed sheave
• Clogged air filter element 4. Primary sliding sheave
• Worn primary sliding sheave
Fuel system 5. Secondary fixed sheave
1. Carburetor • Worn secondary fixed sheave
• Faulty diaphragm 6. Secondary sliding sheave
• Incorrect fuel level • Worn secondary sliding sheave
• Loose or clogged main jet EAS28590
OVERHEATING
EAS28580
FAULTY CLUTCH
Engine
Engine operates but vehicle will not move 1. Cylinder head and piston
1. V-belt • Heavy carbon buildup
• Bent, damaged or worn V-belt 2. Engine oil
• Slipping V-belt • Incorrect oil level
2. Primary sheave cam and primary sheave • Incorrect oil viscosity
slider • Inferior oil quality
• Damaged or worn primary sheave cam
• Damaged or worn primary sheave slider
8-2
TROUBLESHOOTING
Fuel system • Damaged damper rod assembly bolt copper

1. Carburetor washer
• Incorrect main jet setting • Cracked or damaged cap bolt O-ring
• Incorrect fuel level
• Damaged or loose carburetor joint Malfunction
2. Air filter • Bent or damaged inner tube
• Clogged air filter element • Bent or damaged outer tube
• Damaged fork spring
Chassis • Bent or damaged damper rod
1. Brake(s) • Incorrect oil viscosity
• Dragging brake • Incorrect oil level
EAS28670
Electrical system UNSTABLE HANDLING
1. Spark plug 1. Handlebar
• Incorrect spark plug gap • Bent or improperly installed handlebar
• Incorrect spark plug heat range 2. Steering head components
2. Ignition system • Improperly installed lower bracket
• Faulty CDI unit (improperly tightened ring nut)
EAS28640 • Bent steering stem
POOR BRAKING PERFORMANCE • Damaged ball bearing or bearing race
1. Disc brake 3. Front fork leg(s)
• Worn brake pad • Uneven oil levels (both front fork legs)
• Worn brake disc • Unevenly tensioned fork spring (both front
• Air in hydraulic brake system fork legs)
• Leaking brake fluid • Broken fork spring
• Faulty brake caliper kit • Bent or damaged inner tube
• Faulty brake caliper seal • Bent or damaged outer tube
• Loose union bolt 4. Rear shock absorber assembly
• Damaged brake hose • Faulty rear shock absorber spring
• Oil or grease on the brake disc • Leaking oil
• Oil or grease on the brake pad 5. Tire(s)
• Incorrect brake fluid level • Uneven tire pressures (front and rear)
2. Drum brake • Incorrect tire pressure
• Worn brake shoe • Uneven tire wear
• Worn or rusty brake drum 6. Wheel(s)
• Incorrect rear brake lever free play • Incorrect wheel balance
• Incorrect brake camshaft lever position • Deformed cast wheel
• Incorrect brake shoe position • Damaged wheel bearing
• Damaged or fatigued brake shoe spring • Bent or loose wheel axle
• Oil or grease on the brake shoe • Excessive wheel runout
• Oil or grease on the brake drum 7. Frame
• Damaged brake cable • Bent frame
EAS28660
• Damaged steering head pipe
FAULTY FRONT FORK LEGS • Improperly installed bearing race
EAS28710
Leaking oil FAULTY LIGHTING OR SIGNALING SYSTEM
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube Headlight does not come on
• Improperly installed oil seal • Wrong headlight bulb
• Damaged oil seal lip • Too many electrical accessories
• Incorrect oil level (high) • Hard charging
• Loose damper rod assembly bolt • Incorrect connection
• Improperly grounded circuit
8-3
TROUBLESHOOTING
• Poor contacts (main or light switch) • Faulty wire harness

• Burnt-out headlight bulb
Headlight bulb burnt out

• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Faulty main switch
• Headlight bulb life expired
Tail/brake light does not come on

• Wrong tail/brake light bulb
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light bulb
Tail/brake light bulb burnt out

• Wrong tail/brake light bulb
• Faulty battery
• Tail/brake light bulb life expired
Turn signal does not come on

• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
• Faulty battery
Turn signal blinks slowly

• Faulty turn signal switch
• Incorrect turn signal bulb
• Faulty battery
Turn signal remains lit

Turn signal blinks quickly

• Incorrect turn signal bulb
Horn does not sound

• Damaged or faulty horn
• Faulty horn switch
• Faulty battery
8-4
EAS28740 EAS28750
WIRING DIAGRAM COLOR CODE

XA125 (For air induction system B Black
models) Br Brown
1. Main switch Ch Chocolate
Dg Dark green
2. Main fuse
G Green
3. Wire lead L Blue
4. Battery O Orange
5. Starter relay P Pink
6. Starter motor R Red
7. Rectifier/regulator W White
8. AC magneto Y Yellow
9. Right handlebar switch Br/W Brown/White
10. Start switch G/R Green/Red
11. Air temperature sensor G/W Green/White
G/Y Green/Yellow
12. CDI unit
L/B Blue/Black
13. Auto choke unit L/W Blue/White
14. Ignition coil R/W Red/White
15. Spark plug W/L White/Blue
16. Front brake light switch W/R White/Red
17. Rear brake light switch Y/R Yellow/Red
18. Tail/brake light
19. Rear left turn signal light
20. Rear right turn signal light
21. Front right turn signal light
22. Front left turn signal light
23. Auxiliary light
24. Headlight
25. Fuel sender
26. Meter assembly
27. Fuel level meter
28. Meter light
29. Turn signal indicator light
30. Engine trouble warning light
31. High beam indicator light
32. Left handlebar switch
33. Dimmer switch
34. Horn switch
37. Horn
EAS2BK2009 EAS2BK2010
WIRING DIAGRAM COLOR CODE

XA125 (Except for air induction B Black
system models) Br Brown
1. Main switch Ch Chocolate
2. Main fuse Dg Dark green
G Green
3. Wire lead
L Blue
4. Battery O Orange
5. Starter relay P Pink
6. Starter motor R Red
7. Rectifier/regulator W White
8. AC magneto Y Yellow
9. Right handlebar switch Br/W Brown/White
10. Start switch G/R Green/Red
11. Joint G/W Green/White
12. CDI unit G/Y Green/Yellow
13. Auto choke unit L/B Blue/Black
L/W Blue/White
14. Ignition coil
R/W Red/White
15. Spark plug W/L White/Blue
16. Front brake light switch W/R White/Red
17. Rear brake light switch Y/R Yellow/Red
18. Tail/brake light
19. Rear left turn signal light
20. Rear right turn signal light
21. Front right turn signal light
22. Front left turn signal light
23. Auxiliary light
24. Headlight
25. Fuel sender
26. Meter assembly
27. Fuel level meter
28. Meter light
29. Right turn signal indicator light
30. Left turn signal indicator light
31. High beam indicator light
32. Left handlebar switch
33. Dimmer switch
34. Horn switch
37. Horn
XA125 (For air induction system models)
WIRING DIAGRAM
1 Br W/R G/W B
Y/R G/R W/L O
LOCK
OFF (BLACK)
ON 7 8
R W W 12
W W W/R W/R O
W W W/L W/L
B G/R G/W
Br R W W O
W W W W G/R
R W
(BLACK)
14
Y/R Br B B
2
L/W 11 15
G/Y
L/W
Y/R
L/W
9 L/W
3 R/W
13 Y
R 10 W/R
R R L/W Br Br L/W
R OFF
B L L B
ON Y/R Y
L/B L/B
4 R B Y
5 (BLACK) (BLACK) Y
B Br L L/B
B
R/W
B R G/Y
B R
Br Br Br
B
B
36 17 16
Br/W Br Br Br Br
37 Br Br G/Y G/Y G/Y G/Y
P Ch L/B
L Br
Br/W P
Dg Ch Br/W G/Y G/Y
Dg B
B G
(RED) Br L
26 33 L
34 35 L Ch
Br L P Br/W
Ch Dg B Dg
G B
(BLACK)
(RED)
28 28
29 Y Y
30 31 Y
Y G B Ch Dg
27 Y
G Dg Ch B
G/W
G
25
L G/Y
G
B
B Y G B L
(GREEN)
B
22 21 Y
Y L
G
B G
24 23 20 19 18 B
Ch Ch Dg Dg Ch Dg
(GREEN) Y B
B B B B
(BLACK)
L B
B B B B
B L
XA125 (For air induction system models)
WIRING DIAGRAM
1
LOCK
OFF (BLACK)
ON 7 8
12
(BLACK)
14
2
11 15
9
3 13
10
OFF
ON
4
5 (BLACK) (BLACK)
36 17 16
37
32 (BLACK)
(RED)
26 33 34 35
(BLACK)
(RED)
28 28
29
30 31
27
25
(GREEN)
22 21
24 23 20 19 18
(GREEN)
(BLACK)
XA125 (Except for air induction system models)
WIRING DIAGRAM
Br B O
1 W/R W/L Y/R
LOCK 7 8 (B)
R W W
W W W/R W/R O
O
W W
W W W/L W/L
12
B
R W
W W W W 14
(B)
W/R W/L W/L W/R B
Br R W W
Y/R Br B
15
R
9 L/W Y/R
2
L/W
10 13 Y
B
L/W Br Br L/W
G/Y
R L/W B L L B
11 11
L/B L/B Y/R Y
5 L/W B Y
3 R/W (B) (B) Y
R
B Br L L/B
R
4 R
R/W G/Y
B R
B R
6 Br Br Br Br
11 36
Br Br
Br/W
B
37 Br Br 17 16
B
B Ch L/B
Br Br P
Br/W P Br Br
Br/W Br Br
Dg B G/Y G/Y
G/Y G/Y
32 L/B P Br/W (B)
26 Br L G/Y G/Y
33 L
34 35 L Ch
P Br/W
L Br Br L G/Y
B Dg
Dg Ch Ch Dg
B G G B
(B) 11
(R) (R) Y Y G/Y
Y
28 28 29 30 31 G/Y
B
G
G/Y
27 Y G B Ch Dg
Y 11
B
G Dg Ch B G
B
11
Ch Ch Ch Ch
B B
B
25
L G/Y
G G
B
B B
B B Dg Dg Dg Dg
(G) (G)
Y G B L
11 B 22 21 Y
Y L
24 23 20 19 18 B
Ch Ch Dg Dg Ch Dg
11 G
B B B B
Y B L B
(Br) (Br) (G) (G)
B B B (B)
B B
B L
XA125 (Except for air induction system models)
WIRING DIAGRAM
1
LOCK 7 8 (B)
12
14
(B)
15
9
2
10 13
11 11
5
3 (B) (B)
6
11 36
37 17 16
32 (B)
26
33 34 35
(B) 11
(R) (R)
28 28 29 30 31
27
11
11
25
(G) (G)
11 22 21
24 23 20 19 18
11
(Br) (Br) (G) (G)
(B)

M.s.cygnus Z125

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M.s.cygnus Z125

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SERVICE MANUAL

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could

A NOTICE indicates special precautions that must be taken to avoid

TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

IDENTIFICATION ............................................................................................ 1-1

CHECKING THE CONNECTIONS ..................................................................1-4

SPECIAL TOOLS ............................................................................................ 1-6

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

CHECKING THE CONNECTIONS Pocket tester

Tappet adjusting tool 3-4

Pocket tester 3-6

Timing light 3-8

Compression gauge 3-9

Steering nut wrench 3-18, 3-19

Ring nut wrench 3-19, 4-43

T-handle 4-36, 4-38

Damper rod holder 4-36, 4-38

Fork seal driver weight 4-38

Yamaha bond No. 1215 5-10, 5-55

Slide hammer bolt 5-13, 5-15,

Valve spring compressor 5-18, 5-23

Valve spring compressor attachment 5-18, 5-23

Valve guide remover (ø4.5) 5-19

Valve guide installer (ø4.5) 5-19

Piston pin puller set 5-25

Rotor holding tool 5-30, 5-36,

Flywheel puller 5-30

Sheave holder 5-36, 5-41

Locknut wrench 5-36, 5-41

Clutch spring holder arm 5-37, 5-40

Oil seal guide (ø41) 5-40

Digital circuit tester 5-48

Vacuum/pressure pump gauge set 6-2, 6-14

Fuel level gauge 6-8

Ignition checker 7-43

GENERAL SPECIFICATIONS ........................................................................ 2-1

ENGINE SPECIFICATIONS ............................................................................2-2

CHASSIS SPECIFICATIONS ..........................................................................2-9

ELECTRICAL SPECIFICATIONS .................................................................2-12

TIGHTENING TORQUES .............................................................................. 2-14

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-21

LUBRICATION SYSTEM DIAGRAMS .......................................................... 2-23

CABLE ROUTING ......................................................................................... 2-25

Final transmission oil

Rocker arm/rocker arm shaft

Valve, valve seat, valve guide