2008

SERVICE MANUAL

WR250RX(C) WR250XX(C)

LIT-11616-21-66

32C-28197-10

EAS20050

WR250RX(C)/WR250XX(C) SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, December 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-21-66

NOTICE
EAS20070

NOTICE
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 manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:

Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. G Designs and specifications are subject to change without notice.
EAS20080

G This

IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator, a bystander or a person checking or repairing the vehicle. A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle. A NOTE provides key information to make procedures easier or clearer.

CAUTION:

NOTE:

1-1

HOW TO USE THIS MANUAL
EAS20090

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. G The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page “1”. G Sub-section titles appear in smaller print than the section title “2”. G To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section “3”. G Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step “4”. G Symbols indicate parts to be lubricated or replaced “5”. Refer to “SYMBOLS”. G A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc “6”. G Jobs requiring more information (such as special tools and technical data) are described sequentially “7”. 1 3

4 7 2 5 6

1-2

SYMBOLS
EAS20100

SYMBOLS
The following symbols are used in this manual for easier understanding.
NOTE:

The following symbols are not relevant to every vehicle. 1 2 3

4

5

6

7

8

1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10. Gear oil 11. Molybdenum-disulfide oil 12. Brake fluid 13. Wheel-bearing grease 14. Lithium-soap-based grease 15. Molybdenum-disulfide grease 16. Silicone grease 17. Apply locking agent (LOCTITE®) 18. Replace the part

T.

R.

9
E

10
G

11
M

12
BF

13
B

14
LS

15
M

16
S

17
LT

18

New

1-3

EAS20110

TABLE OF CONTENTS
GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING

1 2 3 4 5 6 7 8 9

.

...............................................1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY .................................................................................................................1-8 CIRCLIPS....................................GENERAL INFORMATION IDENTIFICATION ............................................................................................................................................................................ OIL SEALS AND O-RINGS .........................................................1-1 MODEL LABEL .................................................................................1-2 OUTLINE OF THE FI SYSTEM................................................................1-8 GASKETS...............1-1 FEATURES .................1-1 VEHICLE IDENTIFICATION NUMBER....................................................1-10 SPECIAL TOOLS...........................1-4 IMPORTANT INFORMATION .....................................................................................................1-11 1 2 3 4 5 6 7 8 9 ...................................................1-8 REPLACEMENT PARTS .........................................................1-8 BEARINGS AND OIL SEALS..............................................................................................................................................1-2 FI SYSTEM .............................1-8 LOCK WASHERS/PLATES AND COTTER PINS.....1-3 MULTI-FUNCTION DISPLAY.....................................1-9 CHECKING THE CONNECTIONS ................................

1 EAS20150 MODEL LABEL The model label “1” is affixed to the frame. 1 1-1 . This information will be needed to order spare parts.IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe.

8. or operating under a heavy load. improved engine response. better fuel economy. 5. Coolant temperature sensor 14. Despite the same volume of intake air. 6. it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. 4. such as acceleration.FEATURES EAS20170 FEATURES EAS32D1017 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. Crankshaft position sensor 1-2 . EXUP servomotor 12. the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. this model has adopted an electronically controlled fuel injection (FI) system. in place of the conventional carburetor system. 9. Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices. deceleration. To accommodate this need. 1 23 4 5 6 7 8 9 10 14 13 12 11 1. In the conventional carburetor system. the fuel volume requirement varies by the engine operating conditions. Engine trouble warning light Fuel pump Ignition coil Fuel injector Throttle position sensor Intake air pressure sensor 1 Battery Lean angle sensor ECU 10. Intake air temperature sensor 11. 7. 2. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine. The adoption of the FI system has resulted in a highly precise fuel supply. Speed sensor 13. and reduced exhaust emissions. 3. As the requirements for the engine to deliver more performance and cleaner exhaust gases increase.

3 psi) (2. Since fuel is supplied only for the duration of injection. Fuel pump 2.45–2. Control system 1-3 . Intake air temperature sensor 10. 4 11 A 5 2 10 B 9 8 7 6 1 C 3 1.55 kg/cm2). intake temperature sensor and coolant temperature sensor enable the ECU to determine the injection duration. Fuel system B. Air filter case 11. The fuel injector is operated due to signals from the ECU. Throttle bodies 9. As a result. and injects fuel into the intake manifold. The injection timing is determined through the signals from the crankshaft position sensor. Throttle position sensor 5. Signals that are input from the throttle position sensor. ECU 4. intake air pressure sensor. The pressure regulator is installed in the fuel rail. Intake air pressure sensor 8. Crankshaft position sensor 7. crankshaft position sensor. good fuel economy is obtained. Injector 3. Pulsation damper A.FEATURES EAS32D1018 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter.8–36. Intake system C. the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions. and maintains the fuel pressure that is applied to the fuel injector at 245 –255 kPa (34. The injection duration and the injection timing are controlled by the ECU. Coolant temperature sensor 6.

4. all of the display segments of the multi-function display will appear and then disappear. press the “SELECT 2” button until the display changes after the main switch is turned to “ON”. Basic mode Odometer and tripmeter modes Push the “SELECT 2” button to switch the display between the odometer mode and the tripmeter modes A and B in the following order: odometer → tripmeter A → tripmeter B → odometer G Be 3 1. G To switch the speedometer and odometer/ tripmeter displays between kilometers and miles.FEATURES EAS32D1004 MULTI-FUNCTION DISPLAY EWA32D1008 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display. Basic mode: G a speedometer (which shows the riding speed) G an odometer (which shows the total distance traveled) G two tripmeters (which show the distance traveled since they were last set to zero) G a fuel reserve tripmeter (which shows the distance traveled since the fuel level warning light came on) G a clock G a self-diagnosis device G The 1 1. 1 2 3 4 Measurement mode: G a speedometer (which shows the riding speed) G a distance-compensation tripmeter (which shows the accumulated distance traveled since set to zero and which can be calibrated to provide a more accurate tripmeter reading) G a stopwatch (which shows the time that has been accumulated since the start of stopwatch measurement) G a self-diagnosis device NOTE: 6 5 1. G Tripmeter A will automatically reset to zero when changing from the basic mode to the measurement mode or vice versa. 3. “RESET” button “SELECT 1” button “SELECT 2” button Clock/stopwatch Speedometer Odometer/tripmeter/fuel reserve tripmeter 1 2 sure to turn the key to “ON” before using the “SELECT 1”. “SELECT 2” and “RESET” buttons. 6. in order to test the electrical circuit. Tripmeter B indicator “ ” NOTE: multi-function display can be set to the basic mode or the measurement mode. Tripmeter B indicator “ ” 1-4 . G When the key is turned to “ON”. Stopwatch indicator “ ” 2. Tripmeter A indicator “ ”/Distance-compensation tripmeter “ ” 3. 5. Tripmeter A indicator “ ” 1 1. 2.

1. If the fuel level warning light comes on while riding in the measurement mode. 1. 7. Push the “SELECT 1” button and “SELECT 2” button together for at least two seconds to change to the basic mode. Push the “RESET” button. The stopwatch indicator “ ” and the distance-compensation tripmeter indicator “ ” will start flashing. and the second digits will start flashing. Measurement mode (for the stopwatch) When the measurement mode is selected. the clock will not be set and will return to the prior time. and then push the “RESET” button for at least one second. stop it by pushing the “SELECT 1” button and “SELECT 2” button together. Push the “SELECT 1” button for at least two seconds. the stopwatch and the distance-compensation tripmeter must be stopped. Pushing and holding either button will increase or decrease the digits 1-5 . select it by pushing the “SELECT 2” button. 1 The stopwatch must be stopped before changing to the basic mode. push the “SELECT 1” button to increase the digits or “SELECT 2” button to decrease the digits. Clock Turn the key to “ON”.FEATURES NOTE: continuously until the button is released. it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km (3 mi). and indicator “ ” comes on when tripmeter B is selected. Changing from the basic mode to the measurement mode With the odometer selected. Push either select button to set the minutes. To set the clock 1. Fuel reserve tripmeter “F” To reset a tripmeter. 4. 2. NOTE: Indicator “ ” comes on when tripmeter A is selected. push either select button to set the hours. NOTE: When setting the clock. If you do not reset the fuel reserve tripmeter manually. the display will automatically change to the fuel reserve tripmeter mode “F” and start counting the distance traveled from that point. change to the basic mode and push the “SELECT 2” button to display the fuel reserve tripmeter. When the hour digits start flashing. NOTE: If the “RESET” button is not pushed within 30 seconds. Push either select button to set the second digits to zero. Push the “RESET” button for at least two seconds. 5. and the minute digits will start flashing. the stopwatch is displayed and it can be started manually or automatically. push the “SELECT 2” button to switch the display between the various tripmeter and odometer modes in the following order: fuel reserve tripmeter “F” → odometer → tripmeter A → tripmeter B → fuel reserve tripmeter “F” NOTE: The fuel level warning light may not function accurately while riding off road as the fuel level reading changes due to the movement and inclination of the vehicle. If the stopwatch is in operation. Check that the stopwatch is not in operation. In this case. push the “SELECT 1” button and “SELECT 2” button together for at least two seconds to change to the measurement mode. If the fuel level warning light comes on. and then release it to start the clock. Manual start The manual start is the default setting for the stopwatch. 3. 6. Push the “RESET” button. Changing from the measurement mode to the basic mode NOTE: To change from the measurement mode to the basic mode. 2.

chain sprocket sizes. Push the “RESET” button to start the stopwatch. To stop and/or resume counting. If the display indicates any error codes. NOTE: The stopwatch will continue counting when the vehicle is stopped. To stop and/or resume 1-6 . If any of those circuits are defective. repeat steps 3 and 4. Check that the stopwatch measurement is in operation. and the digits in the display will start scrolling from left to right. Stop the stopwatch. 4. note the code number. Calibrating this meter in accordance with the distances specified on the enduro course map will help familiarize the rider with the course. push the “SELECT 1” button and “SELECT 2” button together. Push the “SELECT 1” button and “SELECT 2” button together to stop the stopwatch. push the “SELECT 2” button. In addition. 2. NOTE: 1. Resetting can be made only to the distance-compensation tripmeter or to the distance-compensation tripmeter in combination with the stopwatch. Reset the distance-compensation tripmeter and the stopwatch to zero by pushing the “RESET” button for at least two seconds. repeat steps 2 and 3. Auto start 1. other than specified. Push the “SELECT 1” button for at least two seconds to set the auto start. Self-diagnosis device This model is equipped with a self-diagnosis device for various electrical circuits. Pushing and holding either button will increase or decrease the reading continuously until the button is released. To resume counting. 2. 3. When the vehicle starts moving. calibrating the meter may also be necessary when using tire. and then check the fuel injection 2. To increase the reading. see “Resetting the distance-compensation tripmeter or the distance-compensation tripmeter in combination with the stopwatch”. To reset the stopwatch to zero. To resume stopwatch counting. the stopwatch will start counting. Resetting the distance-compensation tripmeter in combination with the stopwatch 1. NOTE: The stopwatch will continue counting when the vehicle is stopped. 3. etc. the engine trouble warning light will come on. 2. Push the “SELECT 1” button and “SELECT 2” button together to stop the stopwatch. push the “SELECT 1” button. Calibrate the distance-compensation tripmeter as follows. wheel. the stopwatch indicator “ ” and the distance-compensation tripmeter indicator “ ” will start flashing. Reset the distance-compensation tripmeter to zero by pushing the “RESET” button for at least two seconds. push the “SELECT 1” button and “SELECT 2” button together again. Resetting the distance-compensation tripmeter or the distance-compensation tripmeter in combination with the stopwatch NOTE: When the stopwatch is set to auto start. Measurement mode (for calibrating the distance-compensation tripmeter’s reading) The distance-compensation tripmeter is a feature intended to provide a more accurate tripmeter reading for enduro riding.FEATURES counting. and then the display will indicate a two-digit error code. To decrease the reading. Resetting the distance-compensation tripmeter 1. NOTE: Calibrating the reading of the distance-compensation tripmeter is possible regardless of the stopwatch operation.

Error code display ECA32D1007 CAUTION: If the display indicates an error code. 1-7 . 1 1. the vehicle should be checked as soon as possible in order to avoid engine damage.FEATURES system. Refer to “FUEL INJECTION SYSTEM” on page 8-29.

pistons and other parts that have been “mated” through normal wear. remove all dirt. Use oil and grease recommended by Yamaha for all lubrication jobs. All gasket surfaces. During reassembly. EAS20220 LOCK WASHERS/PLATES AND COTTER PINS After removal. 2. During disassembly. REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. always keep mated parts together. When overhauling the engine. When disassembling. After the bolt or nut has been tightened to specification. but inferior in quality. 2. properly oil all mating parts and bearings and lubricate the oil seal lips with grease. Use only the proper tools and cleaning equipment. 1-8 . replace all lock washers/plates “1” and cotter pins. Refer to “SPECIAL TOOLS” on page 1-11. if appropriate. Other brands may be similar in function and appearance. mud. clean all of the parts and place them in trays in the order of disassembly. OIL SEALS AND O-RINGS 1. Oil bearings liberally when installing. lubricate the oil seal lips with a light coat of lithium-soap-based grease. Keep all parts away from any source of fire. EAS20200 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. This will speed up assembly and allow for the correct installation of all parts. seals and O-rings. EAS20210 GASKETS. replace all gaskets. Before removal and disassembly. This includes gears.IMPORTANT INFORMATION EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. 3. bend the lock tabs along a flat of the bolt or nut. Mated parts must always be reused or replaced as an assembly. dust and foreign material. cylinders. EAS20230 4. 5. When installing oil seals “1”. oil seal lips and O-rings must be cleaned.

IMPORTANT INFORMATION ECA13300 CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces. 1-9 . check all circlips carefully and replace damaged or distorted circlips. EAS20240 CIRCLIPS Before reassembly. make sure the sharp-edged corner “2” is positioned opposite the thrust “3” that the circlip receives. Always replace piston pin clips after one use. When installing a circlip “1”.

G As a quick remedy. Pocket tester 90890-03112 Analog pocket tester YU-03112-C NOTE: there is no continuity. 4. etc. Rust/stains → Connect and disconnect several times. bend it up. clean the terminals. 5. couplers. perform steps (1) to (3). moisture. G When G If 3. Disconnect: G Lead G Coupler G Connector 2. checking the wire harness. rust. use a contact revitalizer available at most part stores. Check: G All connections Loose connection → Connect properly. NOTE: If the pin “1” on the terminal is flattened. and connectors for stains. Check: G Continuity (with the pocket tester) 1-10 . Check: G Lead G Coupler G Connector Moisture → Dry with an air blower. Connect: G Lead G Coupler G Connector NOTE: Make sure all connections are tight.CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Check the leads. 1.

NOTE: For U.SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. use part number starting with “90890-”. Special tools. “YU-”. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. and Canada.A. Tool name/Tool No. refer to the list provided below to avoid any mistakes. or “ACC-”.S. For others. part numbers or both may differ depending on the country. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B Illustration Reference pages 5-62 Ring nut wrench 90890-01268 Spanner wrench YU-01268 4-51 Crankshaft installer pot 90890-01274 Installing pot YU-90058 5-63 YU-90058/YU-90059 Crankshaft installer bolt 90890-01275 Bolt YU-90060 5-63 Adapter (M12) 90890-01278 Adapter #3 YU-90063 5-63 1-11 . When placing an order. use part number starting with “YM-”.

Spacer (crankshaft installer) 90890-04081 Pot spacer YM-91044 Illustration Reference pages 5-63 YM-91044 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 6-2 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 6-2 Steering nut wrench 90890-01403 Spanner wrench YU-33975 3-25 Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 3-4 Fork seal driver 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 4-45 1-12 .SPECIAL TOOLS Tool name/Tool No.

8-74. 8-75. 8-79. 8-78. 5-32. Damper rod holder 90890-01454 Illustration Reference pages 4-42. 8-67. 8-66. 8-81 3-9 Timing light 90890-03141 Inductive clamp timing light YU-03141 Pressure gauge 90890-03153 YU-03153 7-6 Vacuum/pressure pump gauge set 90890-06756 Mityvac brake bleeding tool YS-42423 7-6 1-13 . 8-71. 8-76. 8-77.SPECIAL TOOLS Tool name/Tool No. 8-65. 8-72. 4-44 Spoke nipple wrench (8–9) 90890-01522 YM-01522 3-31 Sheave holder 90890-01701 Primary clutch holder YS-01880-A 5-53. 8-73. 5-54 Compression gauge 90890-03081 Engine compression tester YU-33223 3-9 Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1-10.

SPECIAL TOOLS Tool name/Tool No. 8-81 Fuel pressure adapter 90890-03176 YM-03176 7-6 Middle driven shaft bearing driver 90890-04058 Bearing driver 40 mm YM-04058 6-7 Mechanical seal installer 90890-04145 6-7 Universal clutch holder 90890-04086 YM-91042 5-38. 8-80. 5-40 Valve lapper 90890-04101 Valve lapping tool YM-A8998 3-5 Valve spring compressor 90890-04019 YM-04019 5-18. Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Illustration Reference pages 7-7. 5-23 1-14 .

Valve guide remover (ø4.5) 90890-04116 Valve guide remover (4.5 mm) YM-04116 Illustration Reference pages 5-20 Valve guide installer (4.SPECIAL TOOLS Tool name/Tool No. 1215 (Three Bond No.1215®) 90890-85505 5-60 1-15 .5ø) 90890-04118 YM-04118 5-20 Rotor puller 90890-04142 YM-04142 5-53 Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487 8-74 Digital tachometer 90890-06760 YU-39951-B 3-6.5ø) 90890-04117 YM-04117 5-20 Valve guide reamer (4. 3-9 Yamaha bond No.

...........2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS........................................................2-21 ENGINE................................................................2-15 CHASSIS TIGHTENING TORQUES.....................2-25 COOLING SYSTEM DIAGRAMS....................SPECIFICATIONS GENERAL SPECIFICATIONS .........................................................................................................................................................................................................................................................................................................................................................................2-41 Canister (for California).....2-2 CHASSIS SPECIFICATIONS............................................2-1 ENGINE SPECIFICATIONS...................................................................................2-21 CHASSIS...........................................2-39 Throttle body......2-43 1 2 3 4 5 6 7 8 9 .2-31 Front rear brake hose...........................................................................................................................2-15 ENGINE TIGHTENING TORQUES............................................................2-9 ELECTRICAL SPECIFICATIONS..................................................................2-12 TIGHTENING TORQUES..........................................................................................2-29 CABLE ROUTING.............................................2-17 LUBRICATION POINTS AND LUBRICANT TYPES ..............................2-22 LUBRICATION SYSTEM CHART AND DIAGRAMS .........................................................................................2-25 LUBRICATION DIAGRAMS ............................................

6 in) WR250R 134.0 kg (295 lb) (U49) WR250R 135.GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model WR250R 32C1 (U49) WR250R 32C3 (CAL) WR250X 32C2 (U49) WR250X 32C4 (CAL) WR250R 2175 mm (85.9 in) WR250X 1425 mm (56.43 in) (U49) 2300 mm (90.2 in) WR250R 1420 mm (55.61 in) (CAL) WR250R 300 mm (11.0 kg (302 lb) (CAL) 185 kg (408 lb) Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Weight With oil and fuel Maximum load 2-1 .6 in) WR250X 2110 mm (83.0 kg (300 lb) (U49) WR250X 137.9 in) WR250R 930 mm (36.0 kg (298 lb) (CAL) WR250X 136.81 in) (U49) WR250X 260 mm (10.1 in) 810 mm (31.24 in) (CAL) WR250X 265 mm (10.6 in) WR250X 895 mm (35.1 in) WR250R 295 mm (11.4 in) WR250X 1190 mm (46.9 in) WR250R 1230 mm (48.

90 L (0.32 L (0.0 mm (9.qt) Paper Trochoid Less than 0.23 Imp.6 mm (3.00 kgf/cm2) Fuel reserve amount Engine oil Lubrication system Type Recommended engine oil grade Engine oil quantity Total amount Without oil filter element replacement With oil filter element replacement Oil filter type Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Limit Outer-rotor-to-oil-pump-housing clearance Limit Oil-pump-housing-to-inner-and-outer-rotor clearance Limit Bypass valve opening pressure Cooling system Radiator capacity (including all routes) 0.qt) 1.22 Imp.55 US gal) (0.gal) (CAL) WR250X 7.0–137.0 mm (1.qt) 1.10 in) 2-2 .6 L (2.48 US qt) (1.qt) Radiator capacity 0.gal) (U49) WR250X 7.58 Imp.5–87.40 L (1.9 psi) (1.28 Imp.120 mm (0.6 L (2.1 L (0.95 US qt) (0.4 kPa (15.26 US qt) (0.4 mm (4. DOHC 250.2 L (1.01 US gal) (1.0039 in) 0.90 US gal) (1.11 in) 11. SAE 10W-30 or SAE 20W-40 API service SG type or higher.46 Imp.0–600.17 mm (0.32 Imp.2 L (1.0 kPa (72.160 mm (0.ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Starting system Fuel Recommended fuel Fuel tank capacity Liquid cooled 4-stroke.qt) Radiator cap opening pressure 108.0067 in) 500.0 psi) (5.0091 in) 0.090–0.37 kgf/cm2) Radiator core Width 121.0012-0.20 mm (0.90 US gal) (1.030-0.58 Imp.03 × 2.67 Imp.08–1.25 L (0.0079 in) 0.qt) Coolant reservoir capacity (up to the maximum level mark) 0.0047 in) 0.0 × 53.37 US qt) (1.00–6.59 US qt) (1. JASO standard MA 1.0 cm3 Forward-inclined single cylinder 77.34 US qt) (0.79 Imp.gal) Wet sump YAMALUBE 4.0035–0.69 in) Depth 28.gal) (U49) 2.30 L (1.230 mm (0.01 US gal) (1.78 in) Height 246.50 L (1.gal) (CAL) WR250R 7.100 mm (0.14 Imp.80 :1 Electric starter Premium unleaded gasoline only WR250R 7.67 Imp.7–19.0063 in) 0.

0006 in) 98XRH2010-118M Automatic 0.0011–0.0191 in) A B Camshaft runout limit Timing chain Model/number of links Tensioning system Valve.053 mm (1.9685 in) 2-3 .30 mm (0.0031 in) 34.0118 in) 29.550–34.0091–0.8650 in) 0. valve guide Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter A (intake) Valve head diameter A (exhaust) 0.853 mm (1.0178 in) 34.23–0.08 mm (0.953–26.450 mm (1.3681 in) 25.959–21.086 mm (1.7 mm (0.94 cu.850–34.8670 in) 21.972 mm (0.in) 0. valve seat.20 mm (0.750 mm (1.028 in) 15.0270 in) 25.8645–0.0051–0.40–24.ENGINE SPECIFICATIONS Spark plug (s) Manufacturer/model Spark plug gap Cylinder head Volume Warpage limit NGK/CR9EK 0.1850 in) 24.9606–0.0257 in) 25.021 mm (0.0231–1.028–0.015 mm (0.0218–1.8661–0.000–22.0024 in) 0.986–26.886 mm (1.90–30.0020 in) Camshaft Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance Limit Camshaft lobe dimensions Intake A Limit Intake B Limit Exhaust A Limit Exhaust B Limit Chain drive (left) 22.60 mm (0.3957 in) 25.950 mm (1.3642 in) 35.0079 in) 0.05 mm (0.062 mm (0.13–0.6–0.3720–1.024–0.36 cm3 (0.3602–1.3760 in) 34.1772–1.10 mm (1.650 mm (1.

0354–0.47 N/mm (179.1768 in) 4.025–0.010–0.90–1.0039 in) 0.0453 in) 0.69 lb/in) (3.00 mm (1.1776 in) 0.1756–0.90–1.475 mm (0.500–4.037 mm (0.1762–0.490 mm (0.0354–0.0433 in) 0.03 mm (1.70 mm (0.04 in) 0.45 mm (0.100 mm (0.0433 in) 0.1776 in) 4.00 mm (0.15 mm (0.15–1.0433 in) 36.0433 in) C Valve margin thickness D (intake) Limit Valve margin thickness D (exhaust) Limit 1.03 mm (1.0571 in) 1.052 mm (0.ENGINE SPECIFICATIONS A Valve face width B (intake) Valve face width B (exhaust) 1.260 mm (0.0890 in) B Valve seat width C (intake) Valve seat width C (exhaust) 0.10 mm (0.10 mm (0.90–1.0354–0.22 in) 31.10 mm (0.840 mm (0.35 in) 36.03 in) D Valve stem diameter (intake) Valve stem diameter (exhaust) Valve guide inside diameter (intake) Valve guide inside diameter (exhaust) Valve-stem-to-valve-guide clearance (intake) Limit Valve-stem-to-valve-guide clearance (exhaust) Limit Valve stem runout 4.0032 in) 0.42 in) 34.23 mm (1.0335–0.0354–0.90–1.080 mm (0.1772–0.42 in) 34.460–4.35 in) 31.1762 in) 4.0004–0.00 mm (1.512 mm (0.10 mm (0.0004 in) Cylinder head valve seat width (intake) Cylinder head valve seat width (exhaust) Valve spring Free length (intake) Limit Free length (exhaust) Limit Installed length (intake) Installed length (exhaust) Spring rate K1 (intake) 0.512 mm (0.0453–0.22 in) 31.23 mm (1.21 kgf/mm) 2-4 .0015 in) 0.500–4.475–4.0020 in) 0.0724 in) 2.0010–0.85–1.010 mm (0.1772–0.

0305–3.002–17.0020 in) 0.0009 in) 2-5 .54 lb/in) (4.17 kgf/mm) 147.6698 in) 17.54 lb/in) (4.002–0.05–37.6 mm 2.00 N (33.000–77.6689–0.47 N/mm (179.5 °/1.990 mm (3.17 kgf/mm) 31.050 mm (0.0315–3.10 mm (0.50 mm (0.000 mm (0.6694–0.6710 in) 16.00 N (33.05–37.0004–0.991–17.971 mm (0.6681 in) 0.975–76.90 N/mm (233.99 lbf) (14.010–0.69 lb/in) (3.23 kgf) 2.0020 in) 0.043 mm (0.pin-bore clearance 0.47 in) H D Offset Offset direction Piston pin bore inside diameter Limit Piston pin outside diameter Limit Piston-pin-to-piston.99–17.0 mm (0.100 mm (3.010 mm (3.050 mm (0.0311 in) 12.99 lbf) (14.035 mm (0.00–169.00–169.0354 in) 0.21 kgf/mm) 40.0001–0.90 N/mm (233.0319 in) 77.23 kgf) 147.022 mm (0.6693 in) 16.6 mm Winding direction (intake) Winding direction (exhaust) Clockwise Clockwise Cylinder Bore Wear limit Taper limit Out of round limit Piston Piston-to-cylinder clearance Limit Diameter D Height H 77.013 mm (0.5 °/1.0014 in) 0.0039 in) 76.0197 in) Intake side 17.99–17.ENGINE SPECIFICATIONS Spring rate K2 (intake) Spring rate K1 (exhaust) Spring rate K2 (exhaust) Installed compression spring force (intake) Installed compression spring force (exhaust) Spring tilt (intake) Spring tilt (exhaust) 40.

0012 in) 0.ENGINE SPECIFICATIONS Piston ring Top ring Ring type Dimensions (B × T) B T End gap (installed) Limit Ring side clearance Limit 2nd ring Ring type Dimensions (B × T) B T End gap (installed) Limit Ring side clearance Limit Oil ring Dimensions (B × T) B T End gap (installed) Crankshaft Width A Runout limit C Big end side clearance D C C 0.350–0.441 in) 0.115 mm (0.0 mm (0.50 mm (0.75 mm (0.0138–0.11 in) D A Balancer Balancer drive method Clutch Clutch type Clutch release method Clutch lever free play Gear Wet.50 × 2.115 mm (0.80 × 2.09 in) 0.59 in) 2-6 .0008–0.00 mm (2.0045 in) 1.0098 in) 0.065 mm (0.10–0.020–0.0–15.0315 in) 0.95–62.0197 in) 0.0045 in) Taper 0.0177 in) 0.0118–0.0256 in) 0.04 × 0.25 mm (0.25 mm (0.03 × 0.15–0.45 mm (0.0039–0.0012–0.055 mm (0.39–0.0022 in) 0.030 mm (0.0157 in) 61.030–0. cam push 10.30–0.80 mm (0.0026 in) 0.0059–0. multiple-disc Inner push.90 × 2.439–2.06 × 0.650 mm (0.11 in) Barrel 0.75 mm (0.40 mm (0.

318) 26/25 (1.0020 in) 4.813) 29/22 (1.25 V 2320–2590 Ω@20 °C (68°F) 310–326 Ω@80 °C (176 °F) 1450–1650 r/min 28.20 mm (1.90–3.059–0.10 mm (0.62 in) 39.50–1.85 mm (0.786) Shift drum and guide bar 0.120) Chain drive WR250R 43/13 (3.040) 24/27 (0.14 mm (1.100 mm (0.642) 29/16 (1.231) Left foot operation 37/14 (2.1909 in) Auto decomp Wet element Foam air-filter oil or engine oil 38EIS/1 MIKUNI WR250R 32C3 00 (CAL) WR250R 3D71 10 (U49) WR250X 32C3 00 (CAL) WR250X 3D71 10 (U49) 248–278 Ω 3.122 in) 2.050 mm (0.0039 in) 41.114–0.80 mm (0.0039 in) Constant mesh 6-speed Spur gear 78/25 (3.ENGINE SPECIFICATIONS Friction plate thickness Wear limit Plate quantity Clutch plate thickness Plate quantity Warpage limit Clutch spring free length Minimum length Spring quantity Push rod bending limit Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratio 1st 2nd 3rd 4th 5th 6th Shifting mechanism Shift mechanism type Shift fork guide bar bending limit Shift fork thickness Decompression device Device type Air filter Air filter element Air filter oil grade Throttle body Type/quantity Manufacturer ID mark 2.888) 22/28 (0.307) WR250X 42/13 (3.70 mm (0.10 mm (0.1102 in) 7 pcs 1.54 in) 5 pcs 0.75–4.3 kPa (8.4 inHg) (212 mmHg) 80 °C (176 °F) Fuel injection sensor Crankshaft position sensor Intake air pressure sensor output voltage Coolant temperature sensor resistance Idling condition Engine idling speed Intake vacuum Water temperature 2-7 .067 in) 6 pcs 0.

0 mm (0.12–0.ENGINE SPECIFICATIONS Oil temperature Throttle cable free play 60.0 °C (140.00 °F) 3.0–5.20 in) 2-8 .

0 mm (0.08 in) 2.0 mm (10.CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Caster angle Trail Front wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Wheel axle bending limit Rear wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Wheel axle bending limit Front tire Type Size Manufacturer/model Rear tire Type Size Manufacturer/model Tire air pressure (measured on cold tires) Loading condition Front Rear Loading condition Front Rear Semi double cradle WR250R 26.43 in) 2.08 in) 2.37 in) WR250X 76.0 mm (10.08 in) 0.00 kgf/cm2) WR250R 175 kPa (25 psi) (1.25 kgf/cm2) 2-9 .02 in) With tube WR250R 80/100-21M/C 51P WR250X 110/70R17M/C 54H WR250R BRIDGESTONE/TW-301 F WR250X BRIDGESTONE/BT090F RADIAL G With tube WR250R 120/80-18M/C 62P WR250X 140/70R17M/C 66H WR250R BRIDGESTONE/TW-302 F WR250X BRIDGESTONE/BT090R RADIAL G 0–90 kg (0–198 lb) WR250R 125 kPa (18 psi) (1.0 mm (10.00 kgf/cm2) 90–185 kg (198–408 lb) WR250R 150 kPa (22 psi) (1.33 ° WR250R 111.0 mm (2.00 Aluminum 270.0 mm (0.75 kgf/cm2) WR250X 200 kPa (29 psi) (2.67 ° WR250X 25.0 mm (4.0 mm (0.00 kgf/cm2) WR250R 200 kPa (29 psi) (2.08 in) 0.00 Aluminum WR250R 270.25 kgf/cm2) WR250X 200 kPa (29 psi) (2.50 kgf/cm2) WR250X 200 kPa (29 psi) (2.00 kgf/cm2) WR250X 225 kPa (33 psi) (2.50 mm (0.63 in) WR250X 265.60 WR250X 17M/C x MT3.15 WR250X 17M/C x MT4.50 mm (0.63 in) 2.02 in) Spoke wheel WR250R 18x2.99 in) Spoke wheel WR250R 21x1.0 mm (0.

0 mm (0.19 in) WR250X 4.19 in) WR250X 4.2 mm (17.0059 in) 6.29 in) 4.0 mm (10.0 ° 44.0 × 3.5 mm (0.0 mm (11.0 mm (17.0 mm (0.18 in) 4.04 in) 11.0059 in) WR250R 4.45 in) 230.8 mm (0.20–0.63 in) 450.0 mm (0.04 in) 6.CHASSIS SPECIFICATIONS Front brake Type Operation Front brake lever free play Front disc brake Disc outside diameter × thickness Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness (inner) Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Rear brake Type Operation Brake pedal position Rear disc brake Disc outside diameter × thickness Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness (inner) Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Steering Steering bearing type Center to lock angle (left) Center to lock angle (right) Front suspension Type Spring/shock absorber type Front fork travel Fork spring free length Limit Installed length Spring rate K1 Spring stroke K1 Inner tube outer diameter Inner tube bending limit Optional spring available Single disc brake Right hand operation 5.14 in) 0.12 in) WR250X 3.72 in) 441.00 in × 1) DOT 4 Taper roller bearing 44.43 in) 25.47 kgf/mm) 0.2 mm (0.00 mm × 2 (1.04 in) WR250R 11.4 mm (0.73 × 0.25 in) 1.70 mm (0.0 mm (1.14 in) WR250X 298.0 mm (0.27 lb/in) (0.0 mm (0.0 mm (0.0 × 4.0 × 4.16 in) 0.01 in) No 2-10 .06 × 0.0 mm (0.0–8.81 in) 0.36 in) 439.4 mm (0.31 in) WR250R 250.0 mm (0.04 in) WR250R 4.00 mm (0.43 in) WR250X 12.15 mm (0.25 in) 1.8 mm (0.63 in) 46.06 in × 2) DOT 4 Single disc brake Right foot operation 11.40 mm × 1 (1.16 in) WR250R 3.50 in) 27.16 in) 1.0 mm (17.15 mm (0.0 ° Telescopic fork Coil spring/oil damper 270.0 mm (0.0 mm (0.0 mm (0.0–270.60 N/mm (26.16 in) 1.5 mm (0.00–10.5 mm (9.84 × 0.5 mm (9.

0 mm (1.5 mm (8.CHASSIS SPECIFICATIONS Recommended oil Quantity Level Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum Rear suspension Type Spring/shock absorber type Rear shock absorber assembly travel Spring free length Installed length Spring rate K1 Spring stroke K1 Optional spring available Enclosed gas/air pressure (STD) Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum Swingarm Swingarm end free play limit (radial) Swingarm end free play limit (axial) Drive chain Type/manufacturer Link quantity Drive chain slack 15-link length limit Suspension oil 01 613.66 in) 211.0 mm (4.33 in) 206.0–48.11 in) 25 WR250R 12 WR250X 13 3 12 WR250R 10 WR250X 7 1 1.7 psi) (12.0 mm (8.0–95.62 Imp.33 in) 80.74 in) No 1200 kPa (170.0 mm (0.74 in) 220.16 kgf/mm) 0.0 mm (3.3 mm (9.0 mm (0.00 N/mm (456.00–3.0 mm (0.5 mm (8.oz) 105.97 in) 239.50–1.0 mm (1.04 in) 520V/DAIDO 108 WR250R 38.73 US oz) (21.0–50.42 in) 2-11 .0 kgf/cm2) 216.13 in) 12 10 1 19 10 1 Swingarm (link suspension) Coil spring/gas-oil damper 95.80 lb/in) (8.0 cm3 (20.0 mm (8.57–1.04 in) 1.0 mm (8.50 in) 211.89 in) WR250X 40.

21.0 V YTZ7S 12 V. 21.) Engine control unit Model/manufacturer Ignition coil Model/manufacturer Primary coil resistance Secondary coil resistance AC magneto Model/manufacturer Standard output Stator coil resistance Rectifier/regulator Regulator type Model/manufacturer No load regulated voltage Rectifier capacity (DC) Withstand voltage Battery Model Voltage.0 V.310 GS YUASA 0. capacity Specific gravity Manufacturer Ten hour rate amperage Headlight Bulb type Bulb voltage.252 Ω (W-W) Semi conductor-short circuit SH678-11/SHINDENGEN 14.1–14.0 W × 2 12 V.0 Ah 1.0 ° TBDF88/DENSO F6T558/MITSUBISHI 1.61 Ω 8.0 W LED 12 V.60 A Halogen bulb 12 V. 6.0 A 200.9 V 35.50 kΩ F3D7/YAMAHA 14.168–0.0 W × 2 12 V.0 W LED LED LED LED LED LED Constant mesh 2-12 .D.50–11. 5. wattage × quantity Headlight Tail/brake light Front turn signal/position light Rear turn signal light License plate light Indicator light Neutral indicator light Turn signal indicator light High beam indicator light Fuel level warning light Coolant temperature warning light Engine trouble warning light Electric starting system System type 12 V TCI (digital) Digital 10.C.ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage Ignition system Ignition system Advancer type Ignition timing (B.T.0 W/5.19–1. 60 W/55. 350 W@5000 r/min 0.

0 A 7.0 mm (1.18–4.16–9.5 A 7.50 kW 0.0 mm (0.0 Ω ACM33211 M04/MATSUSHITA 86.5 A 7.0 mm (1.50 mm (0. self-canceling device Turn signal blinking frequency Starting circuit cut-off relay Model/manufacturer Coil resistance Headlight relay Model/manufacturer Coil resistance Sidestand relay Model/manufacturer Fuel pump relay Model/manufacturer Coil resistance Fan motor relay Model/manufacturer Fuses Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Fuel injection system fuse Backup fuse Spare fuse SM-14/MITSUBA 0.11 Ω 108–116 dB/2m Full transistor FE246BH/DENSO No 75–95 cycles/min G8R-30Y-V4/OMRON 162.0 A 2-13 .0040–0.60 Ω G8R-30Y-V4/OMRON G8R-30Y-V4/OMRON 162–198 Ω ACM33211 M04/MATSUSHITA 30.0 A 10.06 in) 0.0–198.0 A 1.0 A 4.62 Ω Plane 1 pcs HF-12/NIKKO 3.01–1.39 in) 3.77–34.5 A 7.40–105.0 A 15.27 oz) (730–971 gf) 28.10 in) 27.ELECTRICAL SPECIFICATIONS Starter motor Model/manufacturer Power output Armature coil resistance Brush overall length Limit Brush spring force Commutator diameter Limit Mica undercut (depth) Starter relay Model/manufacturer Amperage Coil resistance Horn Horn type Quantity Model/manufacturer Maximum amperage Coil resistance Performance Turn signal relay Relay type Model/manufacturer Built-in.52 N (25.70 mm (0.14 in) 7.5 A 30.03 in) A3943-072/JIDECO 180.0050 Ω 10.

0 A 10.ELECTRICAL SPECIFICATIONS Spare fuse Spare fuse Spare fuse 15.0 A 7.5 A 2-14 .

TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.8 m•kg.0 m•kg. 7. Outside thread diameter General tightening torques A (nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm B (bolt) Nm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6 15 30 55 85 130 m•kg 0. 7. Distance between flats B. Unless otherwise specified. 8.0 ft•lb 4. 7. tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. 9.5 3.2 ft•lb) 50 Nm (5.0 m•kg. 7.0 m•kg.0 m•kg. To avoid warpage.6 1.0 5.2 ft•lb) 10 Nm (1.4 m•kg. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.5 8. 29 ft•lb) 12 Nm (1.0 m•kg.3 11 22 40 61 94 EAS20340 ENGINE TIGHTENING TORQUES Item Camshaft cap bolt Cylinder head straight screw plug Cylinder head stud bolt (exhaust pipe bolt) Spark plug Cylinder head bolt Cylinder head cover bolt Cylinder head bolt Oil check bolt Cylinder head cover bolt (small head) Balancer weight screw Balancer gear nut Rotor nut Cam sprocket bolt Timming chain tensioner bolt Thread size M6 M12 M8 M10 M10 M6 M6 M8 M6 M6 M14 M12 M7 M6 Q’ty 8 1 2 1 4 2 2 1 5 3 1 1 4 2 Tightening torque 10 Nm (1. 20 ft•lb) 15 Nm (1.5 m•kg.2 m•kg.4 ft•lb) 40 Nm (4. dry threads.2 ft•lb) 28 Nm (2. 7. 7.2 ft•lb) 10 Nm (1.0 m•kg.5 m•kg. tightening torque specifications require clean.2 ft•lb) LT LT Remarks LT lock washer use 2-15 .5 13. 17 ft•lb) 10 Nm (1. 36 ft•lb) 65 Nm (6.0 m•kg.7 ft•lb) 10 Nm (1. Components should be at room temperature. 47 ft•lb) 24 Nm (2. 11 ft•lb) 13 Nm (1.0 m•kg.2 ft•lb) 10 Nm (1.3 m•kg. A.

0 m•kg.2 m•kg.2 ft•lb) 3 Nm (0.2 m•kg.5 m•kg. 1.2 ft•lb) 2 Nm (0.6 m•kg.0 m•kg. 7. 54 ft•lb) Lock washer use LT LT LT LT Remarks LT LT LT Lock washer use 2-16 . 5.2 ft•lb) 6 Nm (0.2 m•kg.2 ft•lb) 2 Nm (0.7 m•kg. 7.3 ft•lb) 10 Nm (1.3 m•kg. 7.7 ft•lb) 6 Nm (0. 14 ft•lb) 20 Nm (2. 7.0 m•kg.2 ft•lb) 2 Nm (0.TIGHTENING TORQUES Item Timing chain guide bolt Plate (impeller shaft side) Oil filter element cover bolt Oil pump bolt Oil pump cover bolt Oil strainer housing bolt Delivery pipe bolt Throttle body joint clamp screw Air filter clamp screw Exhaust pipe nut Muffler and exhaust pipe Muffler bolt Muffler protector bolt Spark arrester bolt EXUP cable pulley double-nut EXUP pully bolt EXUP servo motor bolt EXUP servo motor cover bolt Bearing cover plate bolt Crankcase bolts Crankcase and holder screw Timing mark accessing screw Crankshaft end cover Crankcase cover bolt (left) Crankcase cover bolt (right) Engine oil drain bolt Crankcase and nozzle bolt Primary drive gear nut Clutch spring bolts Locknut (push lever adjusting screw) Clutch boss nut Thread size M6 M6 M6 M6 – M6 M6 M5 M4 M8 M8 M10 M6 M6 M6 M6 M6 M5 M6 M6 M6 M14 M32 M6 M6 M12 M6 M16 M6 M6 M16 Q’ty 4 2 3 2 1 2 1 2 1 2 1 2 3 3 2 2 2 2 6 12 2 1 1 11 12 1 1 1 5 1 1 Tightening torque 10 Nm (1. 7.4 ft•lb) 10 Nm (1.2 m•kg. 7. 7. 30 ft•lb) 7 Nm (0.2 ft•lb) 10 Nm (1.0 m•kg.8 ft•lb) 75 Nm (7.0 m•kg.4 ft•lb) 10 Nm (1.1 ft•lb) 12 Nm (1. 7.0 m•kg.2 m•kg.8 m•kg. 7.2 ft•lb) 10 Nm (1. 7.0 m•kg. 1. 5. 1. 2.8 ft•lb) 8 Nm (0.2 m•kg. 7.6 m•kg. 5.0 m•kg.2 ft•lb) 20 Nm (2.2 ft•lb) 80 Nm (8.2 ft•lb) 10 Nm (1. 4.0 m•kg. 1.0 m•kg.4 ft•lb) 2 Nm (0. 1.0 m•kg.8 m•kg.0 m•kg. 58 ft•lb) 8 Nm (0.0 m•kg.2 ft•lb) 10 Nm (1.2 m•kg.2 ft•lb) 10 Nm (1. 7.4 ft•lb) 10 Nm (1. 14 ft•lb) 10 Nm (1.0 m•kg.4 ft•lb) 20 Nm (2. 4.0 m•kg.0 m•kg. 8.2 ft•lb) 10 Nm (1.2 ft•lb) 10 Nm (1. 7.0 m•kg.3 ft•lb) 2 Nm (0. 14 ft•lb) 42 Nm (4.

5 m•kg. 7.2 ft•lb) 10 Nm (1. 7.2 ft•lb) 10 Nm (1.5 Nm (0.2 ft•lb) 10 Nm (1.2 ft•lb) 23 Nm (2. front lower) Down tube nut Main frame and rear frame Engine protector bolt Drive chain tensioner bolt Thread size M10 M10 M12 M10 M6 M8 Q’ty 1 1/1 3 4 2 2 Tightening torque 67 Nm (6. 13 ft•lb) 10 Nm (1. 41 ft•lb) 10 Nm (1.0 m•kg.0 m•kg. 2.0 m•kg.0 m•kg.2 ft•lb) 10 Nm (1.0 m•kg.0 m•kg. 7.4 ft•lb) 8 Nm (0.0 m•kg.0 m•kg. 7. 7.2 ft•lb) 7 Nm (0.5 ft•lb) 10 Nm (1.2 m•kg. 7. 7.8 ft•lb) 10 Nm (1.7 m•kg.6 m•kg.6 m•kg.8 m•kg.TIGHTENING TORQUES Item Drive sprocket nut Stopper screw (stopper lever) Shift pedal bolt Stator assembly bolt Crankshaft position sensor bolt Neutral switch Thermosensor bolt Drive sprocket cover bolt Right side cover bolt Side cover stay bolt Cylinder bolt Water pump housing cover bolt Coolant drain bolt Clutch cable holder bolt Speed sensor bolt Radiator hose clamp screw Radiator fan bolt Radiator Radiator cover bolt Thermostat cover bolt Seat guide screw Throttle position sensor screw Air induction system pipe bolt Wire harness holder bolt EAS20350 Thread size M18 M8 M8 M6 M6 M5 M12 M6 M6 M6 M6 M6 M6 M6 M6 — M6 M6 M6 M6 M6 M5 M6 M6 Q’ty 1 1 1 3 2 2 1 3 1 2 2 3 1 2 1 6 3 1/1 2 2 2 2 2 1 Tightening torque 95 Nm (9. 41 ft•lb) 113 Nm (11.35 m•kg.2 ft•lb) 4 Nm (0. 16 ft•lb) 18 Nm (1. 69 ft•lb) 22 Nm (2. 7. 2.3 m•kg. 17 ft•lb) Remarks 2-17 .0 m•kg. 5.8 m•kg. 7.2 ft•lb) 10 Nm (1.8 m•kg. 13 ft•lb) 10 Nm (1.2 ft•lb) 10 Nm (1.3 m•kg.2 ft•lb) 10 Nm (1. 7.2 m•kg.0 m•kg.0 m•kg.9 ft•lb) 18 Nm (1. 82 ft•lb) 56 Nm (5.2 ft•lb) 10 Nm (1.2 ft•lb) Remarks Stake the nut LT LT LT LT CHASSIS TIGHTENING TORQUES Item Engine mounting nut (front upper) Engine mounting nut (front. 7. 7. 7. 7.0 m•kg. 1.2 ft•lb) 10 Nm (1.0 m•kg. 48 ft•lb) 56 Nm (5. 7.7 m•kg. 5.4 m•kg.2 ft•lb) 2 Nm (0.2 ft•lb) 10 Nm (1.0 m•kg. 7.0 m•kg.0 m•kg.2 ft•lb) 10 Nm (1.1 ft•lb) 3.

58 ft•lb) 70 Nm (7.5 m•kg.0 m•kg.4 m•kg.0 m•kg.7 m•kg. 38 ft•lb) 80 Nm (8. 29 ft•lb) 53 Nm (5. 7. 58 ft•lb) 80 Nm (8.9 ft•lb) 7 Nm (0.1 ft•lb) 10 Nm (1.7 m•kg. 30 ft•lb) 40 Nm (4.1 ft•lb) 10 Nm (1.2 ft•lb) 16 Nm (1. 22 ft•lb) See NOTE Remarks 2-18 .6 m•kg.7 m•kg.0 m•kg.2 ft•lb) 7 Nm (0.0 m•kg. 2. 20 ft•lb) 40 Nm (4. 7. 12 ft•lb) 7 Nm (0. 2. 5.7 m•kg.7 m•kg.9 ft•lb) 120 Nm (12. 51 ft•lb) 7 Nm (0.0 m•kg.4 m•kg.4 m•kg.2 ft•lb) 10 Nm (1. 5. 62 ft•lb) 42 Nm (4. 7.0 m•kg.0 m•kg.1 ft•lb) 64 Nm (6.1 ft•lb) 7 Nm (0. 2.2 ft•lb) 10 Nm (1.8 m•kg. 7.TIGHTENING TORQUES Item Taillight cover bolt Helmet hanger screw Front fender bolt Sidecover screw Sidecover stay bolt Horn bolt Air scoop stay bolt Air scoop bolt Air scoop and right air panel Rectifier/regulator bolt Recovery tank screw Starter motor leads nut Starter motor bolt Pivot shaft nut Rear shock absorber locknut Rear shock absorber nut (upper) Rear shock absorber nut (lower) Frame and connecting rod nut Connecting rod and relay arm nut Relay arm and swing arm nut Chain case bolt Chain cover bolt Sidestand nut Sidestand switch screw Steering stem nut Lower ring nut Upper bracket pinch bolt Lower bracket pinch bolt Fuel tank bolt Fuel tank bracket bolt Fuel pump bolt Meter nut Meter bracket nut Handlebar upper holder bolt Handlebar lower holder nut Front fork cap bolt Thread size M6 M6 M6 M6 M6 M6 M8 M6 M6 M6 M6 M6 M6 M16 — M10 M10 M14 M14 M14 M6 M6 M10 M5 M24 M28 M8 M8 M6 M6 M5 M5 M6 M8 M12 M48 Q’ty 4 1 4 2 1 1 2 4 2 2 2 2 1 1 1 1 1 1 1 1 2 3 1 2 1 1 4 4 4 3 6 3 1 4 2 2 Tightening torque 10 Nm (1.4 m•kg.0 m•kg.7 m•kg. 5. 17 ft•lb) 20 Nm (2. 2. 46 ft•lb) 4 Nm (0. 29 ft•lb) 30 Nm (30.0 m•kg. 5.2 ft•lb) 4 Nm (0.2 ft•lb) 85 Nm (8. m•kg.5 m•kg.0 m•kg. 7.7 m•kg.1 ft•lb) 4 Nm (0. 5. 5.0 m•kg.3 m•kg. 14 ft•lb) 7 Nm (0. 3.0 m•kg.2 ft•lb) 10 Nm (1.3 m•kg.9 ft•lb) 7 Nm (0.1 ft•lb) 5 Nm (0.1 ft•lb) 7 Nm (0.0 m•kg.7 m•kg.2 m•kg. 5.1 ft•lb) 28 Nm (2. 5. 7.9 ft•lb) 4 Nm (0.6 ft•lb) 10 Nm (1.0 m•kg.4 m•kg. 7. 87 ft•lb) – 23 Nm (2.

2 m•kg.3 m•kg.7 m•kg.9 ft•lb) 10 Nm (1.7 ft•lb) 7 Nm (0. 2.3 m•kg. 5. 4.8 ft•lb) 7 Nm (0. 40 ft•lb) 63 Nm (6.6 m•kg.2 ft•lb) 23 Nm (2.7 m•kg. 11 ft•lb) WR250X only LT LT Remarks LT LT 2-19 .0 m•kg.3 m•kg.4 m•kg.1 ft•lb) 7 Nm (0. lower) Drive chain adjuster locknut Front fork protector bolt Seat bolt Front brake lever adjusting locknut Front brake master cylinder cap Front brake hose holder bolt Rear brake caliper pin plug Rear brake master cylinder lock nut Clutch lever holder bolt Brake hose holder nut Damper rod nut Thread size M22 M16 M8 M6 M8 BC4 M20 M6 M8 M8 M10 M7 M8 M8 M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 M6 M6 M6 M4 M6 M10 M6 M5 M6 M10 Q’ty 2 1 4 6 6 72 1 6 6 2 4 2 2 1 2 1 2 2 2 2 1 1 2 1 6 2 1 2 1 1 1 2 2 2 Tightening torque 55 Nm (5.9 ft•lb) 4 Nm (0.2 ft•lb) 2.3 m•kg.5 Nm (0. 5.1 ft•lb) 17 Nm (1. 12 ft•lb) 7 Nm (0. 5. 5.TIGHTENING TORQUES Item Front fork base valve Front fork axle nut Front wheel axle pinch bolt Front brake disc bolt (WR250R) Front brake disc bolt (WR250X) Spoke (front. 7.1 ft•lb) 7 Nm (0. rear) Rear wheel axle nut Rear brake disc bolt Rear wheel sprocket nut Front brake caliper bolt Union bolt Bleed screw Front caliper support bolt Front caliper pin plug Front master cylinder holder bolt Front brake lever nut Rear master cylinder bolt Rear caliper protector bolt Rear brake caliper support bolt Rear master cylinder bracket bolt Passenger footrest bolt (left) Passenger footrest bolt (right) Drive chain tensioner bolt (upper.7 m•kg.5 m•kg.7 m•kg.25 m•kg. 8.5 Nm (0. 5.0 m•kg. 17 ft•lb) 12 Nm (1.6 m•kg. 90 ft•lb) 12 Nm (1. 17 ft•lb) 16 Nm (1. 7. 17 ft•lb) 30 Nm (30.1 ft•lb) 15 Nm (1. 7. 5. 1.8 ft•lb) 12 Nm (1.3 m•kg. m•kg. 12 ft•lb) 10 Nm (1.5 m•kg. 2.1 ft•lb) 10 Nm (1.3 m•kg. 12 ft•lb) 2. 8. m•kg. 1.7 ft•lb) 35 Nm (3.4 m•kg.2 m•kg. 22 ft•lb) 23 Nm (2.0 m•kg.1 ft•lb) 7 Nm (0.3 ft•lb) 17 Nm (1.2 ft•lb) 7 Nm (0.2 m•kg. 8.25 m•kg. 2.7 m•kg.2 ft•lb) 125 Nm (12.3 m•kg. 17 ft•lb) 30 Nm (30.1 ft•lb) 4 Nm (0. 25 ft•lb) 23 Nm (2.5 m•kg. 5.7 m•kg.7 m•kg. 46 ft•lb) 23 Nm (2.7 m•kg. 22 ft•lb) 6 Nm (0.7 m•kg.5 m•kg. 17 ft•lb) 3 Nm (0.7 ft•lb) 23 Nm (2.

5. 5.1 ft•lb) 2 Nm (0.6 ft•lb) 7 Nm (0.8 m•kg.4 ft•lb) 7 Nm (0. 5.5 m•kg. 1. 3. and retighten it with the 7 Nm (0.1 ft•lb) 5 Nm (0. G Fully loosen the lower ring nut.TIGHTENING TORQUES Item Headlight unit bolt Rear brake hose holder screw Front drive chain guide bolt Delivery pipe screw Canister cover bolt NOTE: G Tighten Thread size M6 M5 M6 M6 M6 Q’ty 2 5 1 2 4 Tightening torque 7 Nm (0.7 m•kg. 27 ft•lb) torque.1 ft•lb) torque. 5.7 m•kg.2 m•kg.7 m•kg. G Turn 2-20 . The rotation motion must be smooth.1 ft•lb) Remarks the lower ring nut with the 38 Nm (3.7 m•kg. the front fork to the left and right.

thrust surfaces Damper assembly shaft. journal Decompression system moving parts Valve stem. idle gear shaft and end Throttle body joint Rotor boss end surface Thrust gear surface Starter clutch assembly Rotor assembly Shaft surface (crankcase bearings) Idle gear-2 inner surface. stem end Valve lifter surface Crank assembly (crankshaft pin surface) Both sliding surfaces of connecting rod big end Piston pin surface Piston surface Cylinder body inner surface Impeller shaft Oil pump assembly shaft Oil pump assembly drain port Idle gear inner diameter and end.LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication points Oil seal lips O-rings Bearings Camshaft cap bolt head Cylinder head bolt threads Camshaft profile. thrust surfaces LS LS Lubrication types LS LS E E M M E M E E E E E E E E E E E E E E E E 2-21 .

1215 (Three Bond No.LUBRICATION POINTS AND LUBRICANT TYPES Lubrication points Push rod 1 surface. 1215®) Yamaha bond No. inner surface Push lever assembly end Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift fork and shift fork guide bars Shift shaft Shift shaft washer. boss Throttle cable end and throttle grip Throttle cable housing inner surface Throttle cable Lubrication types LS LS LS LS LS LS LS LS LS 2-22 . 1215 (Three Bond No. 1215 (Three Bond No. 1215 (Three Bond No. 1215®) Yamaha bond No. 1215®) Yamaha bond No. end Ball (push rod) Primary driven gear assembly. spacer inner surface Cylinder head cover gasket Lubrication types E E E E M M E E E E Yamaha bond No. 1215®) Cylinder head semicircular surface Crankcase mating surface Stator assembly lead grommet EAS20380 CHASSIS Lubrication points Upper bearings and oil seal lip (steering head) Lower bearings and oil seal lip (steering head) Handle lower holder threads Front wheel oil seal (left/right) Rear wheel oil seal (left/right) Brake pedal bolt.

spacer.LUBRICATION POINTS AND LUBRICANT TYPES Lubrication points Brake lever bolt Brake lever and front brake master cylinder Adjusting screw (brake lever) Rear brake master cylinder push rod (boot mount groove) Brake caliper piston seal Brake caliper dust seal Brake caliper support bolt Brake pad support bolt Clutch lever cable Clutch lever bolt Clutch lever Pivot shaft Swing arm bearing. and oil seal Relay arm bearing. and oil seal Connecting rod bearing. collar. collar. collar and oil seal Connecting rod bolt Rear shock absorber assembly lower bolt Rear wheel axle Sidestand switch Sidestand bracket and sidestand Sidestand spring and link Sidestand bolt collar Drive chain tensioner roller collar (upper) S Lubrication types S S S S BF S S LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS 2-23 .

LUBRICATION POINTS AND LUBRICANT TYPES 2-24 .

LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25 .

Oil pan 2-26 . Oil filter 5. Main axle 6. Camshaft 2. Relief valve 10. Oil strainer 11.LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Drive axle 8. Delivery pipe 7. Oil pump 9. Timing chain tensioner 3. Piston cooler 4.

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27 .

5. 3. 8. 7. 6.LUBRICATION SYSTEM CHART AND DIAGRAMS 1. 4. Oil pump assembly Relief valve Main axle Delivery pipe Drive axle Crankshaft Oil filter Oil strainer 2-28 . 2.

COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 8 9 2-29 .

9. 5. Radiator cap Radiator Radiator inlet hose Radiator outlet hose Recovery tank hose Cap Side cover stay Water pump housing cover Impeller shaft 2-30 . 3. 2. 4. 6. 8.COOLING SYSTEM DIAGRAMS 1. 7.

CABLE ROUTING EAS20430 CABLE ROUTING 2-31 .

K. Fasten the rear frame. AC magneto and others. Fuse box 22. coolant temperature sensor lead. sidestand switch lead using a cable tie. Wrap the connectors with a cover for protection. H. O. Positive battery lead 15. Fasten the starter motor lead. Starter relay 6. Pass the AC magneto lead and neutral switch lead through the behind of rectifier regulator. Fasten the magneto lead. Position the recovery tank hose end between the engine bracket and down tube. above the throttle cable. Neutral switch lead 19. Fasten the wire harness. AB. and mount them in a hole of the frame. AK. Z. (The bare conductors of lead can be clamped. D. AJ. Relay unit 14. Negative battery lead 5. and left handlebar switch lead using a cable tie. Clutch cable 29. S. AF. Rectifier/regulator 21. AC magneto lead. Fasten the sidecover stay. Any locking position can be used. Install the cover between of the wire harness (inside) and clutch cable (outside). The AC magneto lead and neutral switch lead must not contact with the horn. To engine. and speed sensor lead using a cable tie. Fasten the wire harness. Wire harness A. M. Clamp the wire harness. U. Starter relay probe 7. AE. Horn lead 25. coolant temperature sensor lead. negative battery lead. coolant temperature sensor lead. Fasten the recovery tank hose to the down tube with clamps. and horn lead using a cable tie. Route the sidestand switch lead to the inside of battery band. place their connectors in the cover. ECU lead 10. Securely insert the wire harness clamp into the T-stud of the rear frame. Cover 28. clultch cable and clutch switch lead (6-pin natural color) at the top of sidecover stay mount boss. Fix the fuse box lead to the side cover stay. Fasten them to the outside of RCU mounting boss (left). Sidestand switch lead 17. Speed sensor lead 4. AC magneto lead. Pass the lead through the hole of rear frame bracket. Radiator fan motor relay 13. An excess must face inward. and through the hole inside of frame tank rail. After cable connection. and neutral switch lead using a cable tie. Y. Starter relay lead 8. clutch cable. Headlight relay 11. Turn signal relay 12. neutral switch lead. Route the wire harness under the clutch cable. The others can be in any position. They must be fixed to the T-stud of the rear frame. Do not route the AC magneto lead. Fasten the rear frame and sidestand switch lead using a cable tie. coolant temperature sensor lead. G. Recovery tank hose 27. Pass the horn lead through the behind of rectifier regulator. P. Neutral switch lead 26. Q. Fasten them between the battery band and battery terminals. neutral switch lead. Fasten the starter motor lead. Recovery tank hose 20. and direct the clamp lock to the inside of the frame. and along the right side of vehicle. Coolant temperature sensor lead 3. 2-32 . and speed sensor lead using a cable tie. AI. They must be fixed to the T-stud of down tube. and speed sensor lead to the frame with a cable tie. and face their cable lock inward. Intake solenoid lead 9. AD. I. Fasten the neutral switch lead. E. Wire harness branch (at left side of vehicle) connected to the fuse box. horn lead and air induction lead above the air cut-off valve assembly. Dimensions of wire harness fastening. neutral switch lead. clutch switch lead. B. Fasten the sidestand switch lead to the rear frame with a cable tie. AH. Fasten the wire harness. X. Securely insert the wire harness clamp into the T-stud of cable holder. horn lead. C.CABLE ROUTING 1. starter motor lead.) AC. The clamp lock must face downwards. Starter motor lead 2. AA. Any locking position can be used. Air induction system pipe 24. negative battery lead. above the throttle cable. An excess must face inward. Rotate the AC magneto lead to the cover. J. Place the clutch cable at the top position. and recovery tank hose to the down tube with a cable tie. and speed sensor lead to the frame with a cable tie. place the connectors in the cover. N. Any locking position can be used. and recovery tank hose to the down tube with a cable tie. F. After connecting the AC magneto lead and neutral switch lead. W. EXUP servo motor lead 16. and the top of cover (for AC magneto lead and neutral switch lead) using a cable tie. AC magneto lead 18. An excess must face forward. Pass the ignition lead under the clutch cable. starter motor lead. negative battery lead. Fasten the sidecover stay. V. R. Fasten the AC magneto lead. Fasten the rear frame cover using a cable tie. L. negative battery lead. Air cut-off valve lead 23. AG. They must be fixed to the T-stud of down tube. T. Pass the ECU lead between the intake solenoid hose and connector. Pass the clutch cable through the inside of FID hose.

CABLE ROUTING 2-33 .

G. Fasten the main switch lead. Throttle position sensor lead 3. The position is a between the halfway from the cable guide and the upperend of the frame number. Fasten the breather hose using a clamp. The clamp must be securely inserted into the frame hole. H. Clamp 2. B. After connecting the main switch lead. Fan motor lead A. and pass them backward through the hole. front brake switch lead. I. D. They must be placed between the front edge of the cable guide and below the “H”.CABLE ROUTING 1. within the range of the handlebar turns from straight ahead to the fully left. Insert the fan motor lead into the concave section of guide air. Fasten the rear brake switch lead to the frame with a clamp. Fasten the throttle position sensor connector cover and the rear brake switch lead using a cable tie. Front edge of the cable guide 2-34 . front brake switch lead. and handlebar switch right lead using a clamp. C. E. and handlebar right lead. and place their connectors in the cover. Any locking position can be used. F. Slightly pull out the end of rear brake switch lead backward.

CABLE ROUTING 2-35 .

C. Fuel pump lead 3. Left rear turn signal light lead 10.CABLE ROUTING 1. Intake air pressure sensor lead 12. A silicone hydrate can be applied when passing the clutch cable or throttle cable through the internal hole of frame tank rails. H. E. Fasten the frame cover. G. and pull them out. The rightmost end of breather hose must be secured (to the front as much as possible). 2-36 . After connection of lead. I. Ignition coil lead 2. D. Taillight lead 9. Pass the injector lead between the fuel pipe. place the connector in the cover so that bare conductors are not exposed. wire harness. B. Throttle cable A. Throttle position sensor lead 5. Clutch cable 13. License plate light lead 8. Injector lead 4. and taillight lead to the rear frame with a cable tie. Fasten the ECU lead using a clamp. Pass the radiator fan motor lead under the breather hose. Fasten the radiator fan motor lead and breather hose using a clamp. F. Right rear turn signal light lead 7. Lean angle sensor lead 11. Fasten the right and rear left turn signal light lead. Rear brake switch lead 6. Fasten the right and left rear turn signal light lead. and taillight lead to the rear frame with a clamp. license plate light lead. and clutch cables to the frame with a cable tie. license plate light lead.

CABLE ROUTING 2-37 .

Pass the front left turn signal light lead through headlight cowling stay as shown. Wire harness (4-pin natural color coupler) A. Meter lead (4-pin natural color coupler) 14. E. clutch cable. F. and connect them inside of the meter. and main switch lead through the wire guide. Cut and remove an excess if any. Left front turn signal light lead 12. Place the clutch cable in the right position. Insert the cable tie into the meter stay. Wire harness (2-pin natural color coupler) 21. P. The others can be in any position. N. clutch switch lead and handlebar switch left lead through the wire guide. H. Insert the wire harness clamps by inserting the two harness clamps into the hole of the meter stay. Stopper (headlight stay) 22. Route the main switch lead upward to the side of head pipe. The others can be in any position. D. Main switch lead 18. Clamp near the end of bent handlebar section using a clamp. Clamp 19. front brake switch lead. and then through the inside of meter stay cable guide from behind the throttle cable. M. Wire harness (green connector) 11. Wire harness (3-pin natural color coupler) 23. Route the handlebar switch right lead and front brake switch lead through the side of main switch. C. Meter lead (3-pin black coupler) 13. Pass the throttle cable between the cable guides of right turn signal light stay and meter stay. Right handlebar switch lead 4. The others can be in any position. Place the throttle cable in the top position. G. B. Install the left handlebar switch lead by inserting them into the space at the side of meter stay. J. Cable guide 17. and connect them. Pass the throttle cable. Clutch cable 7. Do not route the main switch lead to the outside of meter stay cable guide. Throttle cable (accelerator) 2. and connect them inside of the meter. and extend to the side of head pipe. and face the lock downward. 2-38 . Left handlebar switch lead (headlight lead) 16. Throttle cable (decelerator) 3. I. and then through the abobe of meter lead (3-pin black) from behind the handlebar switch lead (3-pin black). Place the lead in the hose so that bare conductors are not exposed. and connect them to the headlight assembly. Auxiliary light lead 20. L. Route the clutch cable in the top position. right handlebar switch lead. Clutch switch lead 5. Left handlebar switch lead 6. O. Fasten the right and left front turn signal light lead and wire harnesses using a cable tie. Pass the right front turn signal light lead through headlight cowling stay as shown. Pass the wire harness. Meter lead (3-pin natural color coupler) 15. and connect them at the meter position. Left front turn signal light lead 9. Insert the meter lead (3-pin natural color coupler) under the meter stay. Route the left front turn signal light lead above the meter lead from behind the handlebar switch left lead.CABLE ROUTING 1. Front brake switch lead 8. Wire harness (brown connector) 10. Pass the left handlebar switch lead above the meter lead (3-pin natural color coupler) as shown. K.

Front rear brake hose Front rear brake hose 2-39 .

Hose guide 3. Rear brake caliper assembly 8. Rear brake disc 7. Rear brake switch 13. Brake pedal 2-40 . Copper washer 9. Rear brake master cylinder 12. Copper washer 5. Front brake hose 2. Union bolt 10. Union bolt 4. Rear brake hose 11. Front brake caliper assembly 6.Front rear brake hose 1.

Throttle body Throttle body 2-41 .

Align the throttle body joint with the hose clamp. L. E. Surge tank A. FID hose 9. Face the clip holder upward of the vehicle. C. Air induction system hose 14. D.Throttle body 1. B. G. 2-42 . Face the yellow paint mark to the left of vehicle. ITS boost hose 13. Radiator inlet hose 6. F. Face the white paint mark to the left side of vehicle. Throttle body joint 8. Vacuum hose 10. Face the clip holder to the front side of vehicle. Pipe 4. K. J. Air filter case assembly 3. Face the white paint mark backward of the vehicle. Throttle body assembly 5. Connect the tank surge hose until it is stopped. Breather hose 2. Install the vacuum hose to the air-filter case until it is stopped. H. Face the white paint upward of the vehicle. Insert the IST boost hose into position until it is stopped. Radiator 7. Face the clip holder to the right front of vehicle. Bend hose 12. Pressure sensor 11. I. Face the white paint mark to the right side of vehicle.

20 in) 45˚ .Canister (for California) Canister (for California) 2-43 5mm (0.

To the throttle body. O. Install the clamp to T stud of the down tube securely. Q. Fuel tank 2. Install the clamp to T stud of the down tube. When the canister cover install. Hose (Fuel tank–roll over valve) 3. Face the clip end upward of the vehicle. Recovery tank hose 8. Face the clip end backward of the vehicle. you may spread the soapy water to the damper as shown. magneto lead. Holder 10. Hold the hose (canister–throttle body) through the 2 clamps securely. E. G. Face the paint leftward of the vehicle. Align the slot of the damper with the pipe of the throttle body side.C. Face the clip end downward of the vehicle. From the roll over valve. M. Face the clip end forward of the vehicle. do not spread the soapy water to the projection of the damper and the hole of the canister cover. Hose 11. K. Clip A. However. Canister 5. Insert the projection of the canister damper to the hole of canister cover. D. Fasten the recovery tank hose and the hose (roll over–canister). I. neutral switch lead. A. N. 2-44 .Canister (for California) 1. P. Roll over valve 9. C. and the hose (roll over valve–canister) using the clamp. B. Fasten the A. recovery tank hose. Face the lock part forward of the vehicle. Align the paint mark with the projection of the bottom of the roll over valve. Canister cover 4. J. Face the paint upward of the vehicle. Route the hose (canister–throttle body) to the up side of the FID hose. and then route it to the inside the clutch wire.C. Neutral switch lead 7. L. H. F. Pass the hose (roll over valve–canister) between the engine head and air cut-off valve assembly. magneto lead 6.

Canister (for California) 2-45 .

...................................................................................3-10 CHANGING THE ENGINE OIL ........................................................................................3-27 CHECKING THE TIRES..........................................................3-8 CHECKING THE IGNITION TIMING....3-9 CHECKING THE ENGINE OIL LEVEL ..........................................................3-24 LUBRICATING THE DRIVE CHAIN...................3-32 LUBRICATING THE SIDESTAND .....................................................................................................................................................3-20 ADJUSTING THE FRONT DISC BRAKE........................................................................................................................................................3-25 CHECKING THE FRONT FORK.............................3-15 CLEANING THE SPARK ARRESTER ............................PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE......................3-1 INTRODUCTION....................................................................3-26 AIR BLEEDING FROM FRONT FORK ........................3-24 CHECKING AND ADJUSTING THE STEERING HEAD.......................................................................3-31 LUBRICATING THE LEVERS................................................................3-31 CHECKING AND LUBRICATING THE CABLES ............................3-32 1 2 3 4 5 6 7 8 9 ..........3-14 CHECKING THE CYLINDER HEAD BREATHER HOSE ....................3-22 BLEEDING THE HYDRAULIC BRAKE SYSTEM .......................3-22 CHECKING THE FRONT BRAKE HOSE .................................................................................3-14 CHECKING THE FUEL LINE ..3-15 ADJUSTING THE EXUP CABLES............................3-1 Periodic maintenance chart for the emission control system .....................................................................................................3-16 CHECKING THE CANISTER (FOR CALIFORNIA ONLY).......................3-31 LUBRICATING THE PEDAL ...............................................................3-22 CHECKING THE REAR BRAKE HOSE......................3-21 CHECKING THE FRONT BRAKE PADS.......3-4 ADJUSTING THE ENGINE IDLING SPEED...............................................................3-23 ADJUSTING THE DRIVE CHAIN SLACK..........................................................................................................................................................3-6 CHECKING THE SPARK PLUG ...................3-31 CHECKING AND TIGHTENING THE SPOKES.......................3-11 ADJUSTING THE CLUTCH CABLE FREE PLAY...................................................................3-12 CLEANING THE AIR FILTER ELEMENT .................................................................................................................................................................3-17 CHECKING THE COOLANT LEVEL..............................................................................................................................................................................3-17 CHECKING THE COOLING SYSTEM...................................3-18 CHASSIS...3-13 CHECKING THE THROTTLE BODY JOINT..............................3-6 ADJUSTING THE THROTTLE CABLE FREE PLAY .......................................................3-20 ADJUSTING THE REAR DISC BRAKE ..................................3-22 ADJUSTING THE REAR BRAKE LIGHT SWITCH..........3-1 ENGINE .............3-4 ADJUSTING THE VALVE CLEARANCE ........................3-17 CHANGING THE COOLANT .......................3-29 CHECKING THE WHEELS ...............................................................................................................................3-20 CHECKING THE BRAKE FLUID LEVEL .................................................3-21 CHECKING THE REAR BRAKE PADS ............................3-26 ADJUSTING THE FRONT FORK LEGS.........3-15 CHECKING THE EXHAUST SYSTEM ...3-27 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY................................................................................3-8 MEASURING THE COMPRESSION PRESSURE...

.........................................................................................................................................................3-33 ...............3-33 CHECKING AND CHARGING THE BATTERY..........................3-33 CHECKING THE FUSES .........................................ELECTRICAL SYSTEM .3-33 ADJUSTING THE HEADLIGHT BEAM .......3-33 REPLACING THE HEADLIGHT BULB ........................................................

ITEM ROUTINE ODOMETER READINGS 600 mi 4000 mi 7000 mi 10000 mi 13000 mi 16000 mi (1000 km) (6000 km) (11000 km) (16000 km) (21000 km) (26000 km) or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months √ √ √ √ √ G Check fuel hoses for cracks 1 * Fuel line or damage. a longer service life and reduce the need for costly overhaul work. G Check condition. √ 3 Spark arrester √ √ √ √ √ 4 * Valve clearance clearance when engine is cold. G Replace if necessary. G Replace gasket(s) if neces- √ √ √ √ √ 6 * Exhaust system √ √ √ √ √ sary. data and technical skills. EAS17580 Periodic maintenance chart for the emission control system INITIAL No. G Check and adjust valve √ Replace. and hose for damage. G Check for leakage. √ √ reed valve. 3-1 . G Clean. √ √ * Since these items require special tools. G Replace if necessary. If followed. G Check breather hose for Every 26600 mi (42000 km) 5 * Crankcase breather system cracks or damage. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. G Tighten if necessary. G Replace any damaged parts. All service technicians should be familiar with this entire chapter. these preventive maintenance procedures will ensure more reliable vehicle operation. √ Replace.PERIODIC MAINTENANCE EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. G Adjust gap and clean. G Replace if necessary. G Replace at 7000 mi (11000 2 Spark plug km) or 12 months and thereafter every 6000 mi (10000 km) or 12 months. have a Yamaha dealer perform the service. G Check the air cut-off valve. Evaporative emis7 * sion control system (For California only) Air induction sys8 * tem G Check control system for damage.

G Replace. and for fluid leakage. G Correct if necessary. G Apply lithium-soap-based grease lightly. 3-2 . G Correct if necessary. G Check bearing assemblies Every 300 mi (500 km) and after washing the motorcycle or riding in the rain 11 * Steering bearings for looseness. G Moderately repack with lith- √ √ √ √ Repack. G Check bearings for smooth √ √ √ √ √ 8 * Wheel bearings Swingarm pivot bearings operation. 7 * Tires G Replace if necessary. G Check all chassis fitting and 12 * Chassis fasteners Brake lever pivot shaft Brake pedal pivot shaft Clutch lever pivot shaft fasteners. √ ium-soap-based grease. G Check operation. G Check chain slack. spoke tight- √ √ √ √ √ Every 4 years √ √ √ √ √ 6 * Wheels ness and for damage. G Replace if necessary. 3 * Front brake G Adjust brake lever free play √ √ √ √ √ √ and replace brake pads if necessary.General maintenance and lubrication chart EAS32164 General maintenance and lubrication chart INITIAL No. G Tighten spokes if necessary. G Apply lithium-soap-based √ √ √ √ √ 13 14 15 √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ grease lightly. align- √ √ √ √ √ ment and condition. G Check runout. ITEM ROUTINE ODOMETER READINGS 600 mi 4000 mi 7000 mi 10000 mi 13000 mi 16000 mi (1000 km) (6000 km) (11000 km) (16000 km) (21000 km) (26000 km) or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months √ √ √ √ √ √ √ √ √ √ √ 1 * Air filter element 2 * Clutch G Clean with solvent. G Check tread depth and for damage. fluid level. G Check operation. fluid level. G Adjust or replace cable. G Check air pressure. G Replace brake pads if nec- √ √ √ √ √ √ essary. G Replace if necessary. G Check bearing assemblies √ √ √ √ √ 9 * for looseness. 4 * Rear brake and for fluid leakage. G Apply silicone grease lightly. 10 Drive chain G Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. G Check operation. 5 * Brake hose G Check for cracks or damage.

Throttle grip hous26 * ing and cable G Adjust the throttle cable free play if necessary. brake service G After disassembling the brake master cylinders and calipers. G Lubricate the throttle grip housing and cable. G Apply Yamaha chain and Change. √ √ √ √ √ 27 * Lights. have a Yamaha dealer perform the service. ITEM ROUTINE ODOMETER READINGS 600 mi 4000 mi 7000 mi 10000 mi 13000 mi 16000 mi (1000 km) (6000 km) (11000 km) (16000 km) (21000 km) (26000 km) or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months √ √ √ √ √ 16 Sidestand pivot G Check operation. G Replace the brake hoses every four years and if cracked or damaged. G Correct if necessary. 24 * Front and rear brake switches G Check operation. G Check operation and free √ √ √ √ √ √ play. data and technical skills. 17 * Sidestand switch G Check operation and replace if necessary. NOTE: From 19000 mi (31000 km) or 36 months. G Check operation and for oil √ √ √ √ √ √ 18 * Front fork leakage. signals and switches √ √ √ √ √ √ * Since these items require special tools. Regularly check the brake fluid levels and fill the reservoirs as required. G Adjust headlight beam. G Apply lithium-soap-based grease lightly.INITIAL No. NOTE: G The G Hydraulic air filter needs more frequent service if you are riding in unusually wet or dusty areas. G Check operation. G Change with ethylene glycol √ √ √ √ √ anti-freeze coolant every 24 months. G Replace if necessary. repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months. always change the fluid. 3-3 . G Check operation and for oil √ √ √ √ √ 19 * Shock absorber assembly Rear suspension link pivots Engine oil Engine oil filter element leakage. G Change (warm engine √ √ √ √ √ 20 * 21 22 √ √ √ √ √ √ √ √ √ √ √ before draining). and change the brake fluid. G Replace if necessary. G Every two years replace the internal components of the brake master cylinders and calipers. 23 * Cooling system G Replace if necessary. G Check hoses for cracks or damage. √ √ √ √ √ √ 25 * Control cables cable lube or engine oil SAE 10W-30 thoroughly. G Replace. G Check operation.

Remove: G Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. 1. Remove: G Ignition coil assembly G Spark plug Refer to “CAMSHAFT” on page 5-6. 3-4 . b a c.0051–0. Remove: G Seat G Side cover (left/right) G Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Remove: G Throttle cable G Clutch cable Refer to “CAMSHAFT” on page 5-6.0091–0. NOTE: clearance adjustment should be made on a cold engine. Align TDC mark “a” of the generator rotor with mark “b” of the generator rotor cover. Out of specification → Adjust. the piston must be at top dead center (TDC) on the compression stroke.13–0. 2. Measure: G Valve clearance a. Remove: G Timing mark accessing screw “1” G Crankshaft end cover “2” 1 G Valve a. 3.23–0.20 mm (0. 6. G Air vent hose (Air induction) G Cylinder head cover Refer to “CAMSHAFT” on page 5-6. 5. Turn the crankshaft counterclockwise. Adjust: G Valve clearance MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM 2 7. Remove: G Cam chain tensioner G Camshaft cap G Intake camshaft G Exhaust camshaft NOTE: G Refer to “CAMSHAFT” on page 5-6. G When the valve clearance is to be measured or adjusted.ENGINE EAS20471 ENGINE EAS20520 Out of specification → Adjust.0118 in) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. Drain: G Coolant Refer to “CHANGING THE COOLANT” on page 3-20. Special thickness gauge 90890-03180 Feeler gauge set YU-26900-9 1 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 8. at room temperature.30 mm (0. Valve clearance (cold) Intake 0. b.0079 in) Exhaust 0. G Fuel tank Refer to “FUEL TANK” on page 7-1. Measure the valve clearance with a thickness gauge “1”. 4.

45 in) 25 thicknesses in 0. Install the new valve pad “3” and the valve lifter “4”. direct the pad having a number on it toward the lifter. G Lubricate the valve lifter with molybdenum disulfide oil. G The valve lifter must turn smoothly when rotated by hand. timing chain and the camshaft caps. connect the cam chain using a wire so that it does not drop in the crankcase. 120–240 120–240 mm (4. 7. 1 2 Valve lapper 90890-04101 Valve lapping tool YM-A8998 NOTE: thickness of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter.002 in) increments b. the valve pad number must be rounded in order to reach the closest equivalent to the original. e. G Since valve pads of various sizes are originally installed. G Remember that the replacement valve pad number is a rough value. R. M G Cover 3 M NOTE: c. Repeat the above procedure until you have the standard valve clearance.05 mm (0. Valve pad range Valve pad thickness Available valve pads NOTE: Nos. G Install the valve lifter and the valve pad in the correct place.0 m•kg. Install the exhaust and intake camshafts. installing the valve pad. Select the proper valve pad from the following table. G Lubricate the valve pad with molybdenum disulfide grease. Camshaft cap bolt 10 Nm (1. d. 4 G The the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.72–9.2 ft•lb) G When T. G Make a note of the position of each valve lifter “1” and valve pad “2” so that they can be installed in the correct place. Remove the valve lifter “1” and the valve pad “2” with a hand valve lapper.ENGINE G Before removing the cam chain and camshaft. 3-5 .

3-6 . 1. Install: G Digital tachometer (Red/black ignition coil leads) EAS20640 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play. Use a temperature probe tester “1” and contact it to the drain bolt thread. G Lubricate the camshaft bearings. G Align the camshaft sprocket marks with the edge of the cylinder head. 1.00 °F) 3. Adjust the engine idling speed by turning the adjust screw “1” in direction “a” or “b”.0 mm G Throttle cable free play (Cable free play at surface of throttle grip flange) 3–5 mm 1 Oil temperature 60. repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 10.ENGINE NOTE: G Refer to “CAMSHAFT” on page 5-6. camshaft lobes and camshaft journals. reverse the removal procedure.0 °C (140. Adjust: G Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-8. and the engine should have adequate compression. G Turn the crankshaft counterclockwise several full turns to seat the parts. the air filter element should be clean. Engine idling speed 1450–1650 r/min 5. 9. g. Start the engine and let it warm up until it reaches the specified temperature. 2. install the exhaust camshaft. Install: G All removed parts NOTE: a 1 b For installation. EAS20590 ADJUSTING THE ENGINE IDLING SPEED NOTE: Direction “a” Direction “b” Engine idling speed → Decrease Engine idling speed → Increase Prior to adjusting the idling speed. Digital tachometer 90890-06760 YU-39951-B 4.0–5. Note the following points. Check: G Throttle cable free play “a” Out of specification → Adjust.Fill the coolant as specification. Measure: G Engine idling speed Out of specification → Adjust. Measure the valve clearance again. G First. If the valve clearance is still out of specification. Throttle cable free play 3. and then check the coolant level. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 6. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL a. Adjust: G Engine idling speed MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM f. the engine idling speed should be adjusted properly.

use the adjusting nut on the handlebar side.0 mm (0. Install: G Fuel tank Refer to “GENERAL CHASSIS” on page 4-1. d. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Throttle body side a. Loosen the locknut “1”. c. Adjust: G Throttle cable free play NOTE: NOTE: If the specified throttle cable free play cannot be obtained on the throttle body side of the cable.ENGINE b a a a 2 1 b 4 3 Throttle cable free play 3. the accelerator cable is pulled. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Handlebar side a. 1 a b When the throttle is opened. Tighten the locknuts “1”. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. Tighten the locknut. c. e. Loosen the locknut “1” on the decelerator cable. Loosen the locknut “3” on the accelerator cable. 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 change. Direction “b” Throttle cable free play is decreased. “3”. Direction “a” Throttle cable free play is increased.0–5. b. 2 EWA12920 WARNING After adjusting the throttle cable free play. 3.12–0. Remove: G Seat G Side cover (left/right) G Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Turn the adjusting nut “2” in direction “a” or “b” to take up any slack on the decelerator cable. G Air scoop (left/right) G Side cover (left/right) 3-7 .20 in) 2. G Fuel tank Refer to “FUEL TANK” on page 7-1. Direction “b” Throttle cable free play is decreased. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. b. Turn the adjusting nut “4” in direction “a” or “b” until the specified throttle cable free play is obtained. Direction “a” Throttle cable free play is increased.

024–0. R. Check: G Spark plug type Incorrect → Change. Make sure all connections are tight and free of corrosion.ENGINE G Seat Refer to “GENERAL CHASSIS” on page 4-1. G Fuel tank Refer to “GENERAL CHASSIS” on page 4-1. Apply silicone hydrate to the sealing point of the ignition coil. 9. Remove: G Ignition coil assembly “1” G Spark plug Refer to “CAMSHAFT” on page 5-6. G Insulator Abnormal color → Replace the spark plug. a a 7. Spark plug gap 0. 1.3 m•kg. EAS20700 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing. 2. Measure: G Spark plug gap “a” Out of specification → Regap.  Before installing the spark plug. Check: G Electrode Damage/wear → Replace the spark plug. Remove: G Seat G Side cover (left/right) G Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Clean: G Spark plug (with a spark plug cleaner or wire brush) 6. Connect: G Ignition coil assembly G Ignition coil assembly lead ECA13330 CAUTION: NOTE: Before removing the spark plug. 8.4 ft•lb) NOTE: T. Install: G Fuel tank Refer to “GENERAL CHASSIS” on page 4-1. G Air scoop (left/right) G Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 2. and install the ignition coil assembly by positioning its connector to the right.6–0. 5. Install: G Spark plug Spark plug 13 Nm (1. check the wiring connections of the entire ignition system. Connect: G Timing light “1” G Digital tachometer 3-8 . Normal color is medium-to-light tan. Manufacturer/model NGK/CR9EK 4. clean the spark plug and gasket surface.7 mm (0. Remove: G Timing mark accessing screw G Seat G Side cover (left/right) G Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 3.028 in) EAS20690 CHECKING THE SPARK PLUG 1. 9.

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. Measure: G Valve clearance Out of specification → Adjust. G Fuel tank Refer to “FUEL TANK” on page 7-1. Start the engine.ENGINE (Red/black ignition coil leads) Timing light 90890-03141 Inductive clamp timing light YU-03141 Digital tachometer 90890-06760 YU-39951-B 1 G Digital tachometer 5. warm it up for several minutes. Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-5. warm it up for several minutes. and then turn it off. Remove: G Seat G Side cover (left/right) G Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 1. Remove: G Ignition coil assembly G Spark plug ECA13340 3. 3. 2. use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders. and then let it run at the specified engine idling speed. G Timing mark accessing screw EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. Disconnect: G Ignition coil assembly coupler 5. Install: G Compression gauge “1” Compression gauge 90890-03081 Engine compression tester YU-33223 NOTE: The ignition timing is not adjustable. Install: G Air scoop (left/right) G Side cover (left/right) G Seat Refer to “GENERAL CHASSIS” on page 4-1. Check the firing range as shown. 4. 6. Remove: G Timing light 3-9 . CAUTION: Before removing the spark plugs. Start the engine. NOTE: Insufficient compression pressure will result in a loss of performance. Check: G Ignition timing MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Oil temperature 55–65°C Engine idling speed 1450–1650 r/min b. Incorrect firing range → Check the ignition system.

3. 9. sure the vehicle is upright. G Air scoop (left/right) G Side cover (left/right) G Seat Refer to “GENERAL CHASSIS” on page 4-1. valves. pour a teaspoonful of engine oil into the spark plug bore and measure again. Stand the vehicle on a level surface.5 kg/cm2) Compression pressure (Minimum) 740 kPa (105 psi) (7. If the compression pressure is below the minimum specification. With the throttle wide open.4 ft•lb) 9.5 kg/cm2) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Spark plug 13 Nm (1. G Make 2. Install: G Spark plug 7. Carbon deposits → Eliminate.Install: G Fuel tank Refer to “FUEL TANK” on page 7-1.3 m•kg. Start the engine. c. valve surfaces and piston crown for carbon deposits.4 kg/cm2) Compression pressure (Maximum) 950 kPa (135 psi) (9. Refer to the following table. Measure: G Compression pressure Out of specification → Refer to steps (c) and (d). EAS20730 a. check the cylinder head. T. and then turn it off. Compression pressure (with oil applied into the cylinder) Reading Higher than without oil Diagnosis Piston ring (s) wear or damage → Repair. G Make sure there is no compression leakage from the connecting section of the compression gauge. b. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 8. If the compression pressure is above the maximum specification. cylinder head gasket or piston possibly defective → Repair. crank the engine until the reading on the compression gauge stabilizes. b a 3-10 .Connect: G Ignition coil assembly lead coupler 11.ENGINE 1 Same as without oil Piston. the vehicle on a suitable stand. NOTE: G Place G Make use the battery is fully charged when taking measurements. warm it up for several minutes. Compression pressure (Standard) 850 kPa (121 psi) (8. d. Install: G Ignition coil assembly 10. Check: G Engine oil level The engine oil level should be between the minimum level mark “a” and maximum level mark “b”. R. NOTE: CHECKING THE ENGINE OIL LEVEL 1. Below the minimum level mark → Add the recommended engine oil to the proper level. Set the main switch to “ON”.

Remove: G Engine oil filler cap “1” G Engine oil drain bolt “2” (along with the gasket) CAUTION: 1 oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Start the engine. Check the engine oil level again. 4. Replace the O-rings “3”. Install the new oil filter element and the oil fil- 3-11 . SAE 10W-30 or SAE 20W-40 Recommended engine oil grade API service SG type or higher. Start the engine. G Do not allow foreign materials to enter the crankcase. warm it up for several minutes. 2 3 1 c. JASO standard MA ECA13360 3. warm it up for several minutes. do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled “ENERGY CONSERVING II”. 2. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Drain: G Engine oil (completely from the crankcase) 5. Place a container under the engine oil drain bolt. Remove the oil filter element cover “1” and oil filter element “2”. Before checking the engine oil level. If the oil filter element is also to be replaced. and then turn it off. EAS20810 CHANGING THE ENGINE OIL 1. NOTE: Before checking the engine oil level. wait a few minutes until the oil has settled.ENGINE Type YAMALUBE 4. wait a few minutes until the oil has settled. Therefore. and then turn it off. 0 10 30 50 70 90 110 130 ˚F G Engine YAMALUBE 4 (10W-30) or SAE 10W-30 YAMALUBE 4 (20W-40) or SAE 20W-40 –20 –10 0 10 20 30 40 50 ˚C 2 4. 5. perform the following procedure. NOTE: 1 b.

0 mm (0. c. 11. turn the engine off so that it will not seize. 7. a 3-12 .2 ft•lb) T. R. Start the engine and keep it idling until engine oil starts to seep from the oil check bolt.59 US qt) (1. Check: G Clutch cable free play “a” Out of specification → Adjust.qt) Without oil filter element replacement 1. Install: G Engine oil drain bolt (along with the gasket) Engine oil drain bolt 20 Nm (2.40 L (1. Check the engine oil passages. e.30 L (1.0–15.39–0. the oil filter cartridge and the oil pump for damage or leakage. and then turn it off. warm it up for several minutes. Refer to “OIL PUMP AND BALANCER GEAR” on page 5-45.0 m•kg. Check: G Engine oil drain bolt gasket G Oil filter element drain bolt gasket Damage → Replace. Slightly loosen the oil check bolt “1”. Loosen the locknut “1”.ENGINE ter element cover. If no engine oil comes out after one minute.Check: G Engine oil pressure MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. R. 2.48 US qt) (1.14 Imp. Oil check bolt 10 Nm (1.Start the engine. 13.Check: G Engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL” on page 3-12.0 m•kg. Adjust: G Clutch cable free play MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM T. 7. Tighten the oil check bolt to specification.Check: G Engine (for engine oil leaks) 12. d. Fill: G Crankcase (with the specified amount of the recommended engine oil) Engine oil quantity Total amount 1.37 US qt) (1.59 in) Handlebar side a.qt) 9. R.50 L (1. Start the engine after solving the problem (s) and check the engine oil pressure again. b.qt) With oil filter element replacement 1. Turn the adjusting bolt “2” in direction “a” or “b” until the specified clutch cable free play is T.0 m•kg.32 Imp.2 ft•lb) 1 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 6. Clutch lever free play 10. 7. 14 ft•lb) 8.23 Imp. Install: G Engine oil filler cap 10. b. Oil filter element cover bolt (M10) 10 Nm (1.

Remove: G Right side cover Refer to “GENERAL CHASSIS” on page 4-1. 2. Direction “a” Clutch cable free play is increased. 12 EAS20941 CLEANING THE AIR FILTER ELEMENT 1. such as gasoline. Check: G Air filter element Damage → Replace. If dust or water or both collects in this hose. a 2 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3-13 . Direction “b” Clutch cable free play is decreased. c. 5. e. 3. Remove the air filter element assembly “1” by removing the clip “2”. d. Tighten the locknut “1”. 6. 7. Such solvents may cause a fire or an explosion. use the adjusting nut on the clutch cable side. Open the air filter case cover by removing its screws. Loosen the locknuts “1”. clean the air filter case and air filter check hose.ENGINE obtained. Clean: G Air filter element (with solvent) EWA13020 WARNING Never use low flash point solvents. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Clutch cable side a. Turn the adjusting bolt “2” in direction “a” or “b” until the specified clutch cable free play is obtained. NOTE: After cleaning. Slide the clutch cable cover. 8. gently squeeze the air filter element to remove the excess solvent. Remove: G Air filter element Remove the air filter element from the air filter element frame. Return the clutch cable cover to its original position. replace the air filter element. Tighten the locknut “1”. 4. Direction “b” Clutch cable free play is decreased. Remove: G Air filter check hose NOTE: On the bottom of the air filter case is a check hose. Direction “a” Clutch cable free play is increased. 2 1 a b NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable. Apply the recommended oil to the entire surface of the air filter element and squeeze out the excess oil. The air filter element should be wet but not dripping. b. c. to clean the air filter element. ECA13430 CAUTION: 1 b Do not twist the air filter element when squeezing it.

3-14 . Fuel tank G Fuel tank Refer to “GENERAL CHASSIS” on page 4-1. 1. G Air scoop (left/right) G Side cover (left/right) G Seat Refer to “GENERAL CHASSIS” on page 4-1. 2. CHECKING THE FUEL LINE The following procedure applies to all of the fuel. 2. G Fuel tank Refer to “FUEL TANK” on page 7-1.Install: G Air filter cover 12. G Fuel tank Refer to “FUEL TANK” on page 7-1. Remove: G Seat G Side cover (left/right) G Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Remove: G Seat G Side cover (left/right) G Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 1 3. Loose connection → Connect properly. Unfiltered air will cause rapid wear of engine parts and may damage the engine. G Air scoop (left/right) G Side cover (left/right) G Seat Refer to “GENERAL CHASSIS” on page 4-1.Install: G Air filter element assembly 11. Install: G Fuel tank Refer to “FUEL TANK” on page 7-1. G Insulator manifold “2” Cracks/damage → Replace. 10. vacuum and breather hoses. Install: G Air filter element frame ECA14401 CAUTION: Never operate the engine without the air filter element installed. Check: G Fuel hose “1” Cracks/damage → Replace. EAS21020 CHECKING THE THROTTLE BODY JOINT 1. Check: G Throttle body joint “1” Cracks/damage → Replace. EAS21030 9.Install: G Side cover (right) Refer to “GENERAL CHASSIS” on page 4-1. Operating the engine without the air filter element will also affect carburetor synchronization. leading to poor engine performance and possible overheating.ENGINE Recommended oil Foam air filter oil or engine oil 2 1 3.

R. G Air scoop (left/right) G Side cover (left/right) G Seat Refer to “GENERAL CHASSIS” on page 4-1. 2.7 m•kg. 3-15 . Check: G Cylinder head breather hose “1” Cracks/damage → Replace. Remove: G Muffler protector 2. CAUTION: Make sure the cylinder head breather hose is routed correctly. EAS21080 3 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. ECA14920 Exhaust pipe nut “1” 20 Nm (2. 2. 5. 3. 14 ft•lb) Muffler and muffler bracket bolt “3” 42 Nm (4. G Fuel tank Refer to “FUEL TANK” on page 7-1.0 m•kg. Remove: G Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. Check: G Tightening torque 4. Install: G Fuel tank Refer to “FUEL TANK” on page 7-1. 30 ft•lb) 1 T. Check: G Exhaust pipe G Muffler Cracks/damage → Replace.2 m•kg. Remove: G Seat G Side cover (left/right) G Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1. 1 2 3. G Gasket Exhaust gas leaks → Replace. Loose connection → Connect properly. R.1 ft•lb) EAS21100 ADJUSTING THE EXUP CABLES 1. Install: G Muffler protector Muffler protector bolt 7 Nm (0.ENGINE EAS21050 CHECKING THE CYLINDER HEAD BREATHER HOSE 1. 1.0 m•kg. 14 ft•lb) Exhaust pipe and muffler bolt “2” 20 Nm (2. Remove: G EXUP valve pulley cover “1” T.

c. 1 Locknut 6 Nm (0. a. Turn the adjusting bolt “2” of pulley cable 2 to the position when the cable has the same 3-16 . Tap the tailpipe lightly with a soft-face hammer or suitable tool. R. 4. b. Clean: G Spark arrester MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM EWA14680 WARNING Select a well-ventilated area free of combustible materials. Move EXUP pully by self-diagnostics diagnosis mode No. c.ENGINE tension as for pulley cable 1. Turn the adjusting bolt “2” of pulley cable 1 to the position just when the EXUP pulley starts operating.“53”. Install the EXUP valve pully cover. b. EAS28970 CLEANING THE SPARK ARRESTER 1. G Do not start the engine when removing the tailpipe from the muffler. Remove the bolt “1”. 3.6 m•kg. Adjust: G EXUP cable free play NOTE: Install pulley cable 1 (black chrome plated) to stamp 1 side. d. then use a wire brush to remove any carbon deposits from the spark arrester portion “a” of the tailpipe and the inner contact surfaces of the muffler. Check: G EXUP system operation NOTE: Check operation by self-diagnostics diagnosis mode No. and install pulley cable 2 (white chrome plated) to stamp 2 side. Tighten both locknuts “1” with specification. Loosen both locknuts “1”.3 ft•lb) 2 T. Refer to “FUEL INJECTION SYSTEM” on page 8-29. “53”. EXUP cable free play 0 mm 2 1 f. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Remove the tailpipe “2” by pulling it out of the muffler. G 5. Check: G EXUP cable free play (at the EXUP valve pulley) G Connect the battery power cables to the servo motor. 4. and measure its play. Install: G Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. e. G Always let the exhaust system cool before performing this operation. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 6.

e. 2. Install: G Canister cover Canister cover bolt 10 Nm (1. correct the antifreeze concentration of the coolant. soft water may be used. 3. T. Check: G Coolant level CHECKING THE CANISTER (FOR CALIFORNIA ONLY) 1.ENGINE G Make sure the vehicle is upright. warm it up for several minutes. 8. Check: G Radiator “1” R. NOTE: Before checking the coolant level. Start the engine. 2. a a b d. Insert the tailpipe into the muffler and align the bolt holes.2 m•kg. Insert the bolt and tighten it. If water is used instead of coolant check. 1 2 2. Check: G Canister G Hose Cracks/damage → Replace. Install: G Air scoop (left) G Seat Refer to “GENERAL CHASSIS” on page 4-1. and then turn it off. wait a few minutes until it settles. Stand the vehicle on a level surface.2 ft•lb) EAS21110 CHECKING THE COOLANT LEVEL 1. 5. However. 7. R. Remove: G Seat G Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1.7 ft•lb) (Apply the molybdenum-disulfide grease) ECA13470 CAUTION: G Adding LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21090 water instead of coolant lowers the antifreeze content of the coolant. 3-17 . Remove: G Canister cover Refer to “CANISTER (FOR CALIFORNIA)” on page 7-13. and if necessary. EAS21120 the vehicle on a suitable stand. NOTE: G Place T. 4.0 m•kg. CHECKING THE COOLING SYSTEM 1. Below the minimum level mark → Add the recommended coolant to the proper level. Check: G Coolant level The coolant level should be between the maximum level mark “a” and minimum level mark “b”. 3. G Use only distilled water. if distilled water is not available. G Fuel tank Refer to “FUEL TANK” on page 7-1. Spark arrester bolt 12 Nm (1. Remove: G Seat G Air scoop Refer to “GENERAL CHASSIS” on page 4-1. 6.

Therefore. Install: G Copper washer New G Coolant drain bolt (water pump) Coolant drain bolt (engine) 10 Nm (1. When the hissing sound has stopped. do not remove the radiator cap when the engine is hot. “THERMOSTAT” on page 6-4 and “WATER PUMP” on page 6-6. Refer to “RADIATOR” on page 6-1. Install: G Reservoir tank 9. Remove: G Seat G Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1.0 m•kg. Remove: G Radiator cap “1” Remove the radiator cap by removing lock screw “2”. Install: G Fuel tank Refer to “FUEL TANK” on page 7-1.2 ft•lb) 8. R. When the engine has cooled. 5. open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. EAS21130 CHANGING THE COOLANT 1. Scalding hot fluid and steam may be blown out. 7. press down on the radiator cap and turn it counterclockwise to remove. G Fuel tank (left/right) G Seat Refer to “GENERAL CHASSIS” on page 4-1. 6. 1 1 2 EWA13030 2 3 WARNING 3. 3-18 . Drain: G Coolant (from the recovery) 4. Connect: G Coolant reservoir hose T. Remove: G Coolant reservoir hose “1” G Recovery tank “2” 1 A hot radiator is under pressure.ENGINE G G Radiator inlet hose “2” Radiator outlet hose “3” Cracks/damage → Replace. Drain: G Coolant (from the engine and radiator) 7. 2. Remove: G Coolant drain bolt (water pump) “1” (along with the copper washer) 1 2 3. which could cause serious injury.

Install: G Coolant reservoir cap 14. correct the antifreeze concentration of the coolant. 16. and if necessary.qt) ter.95 US qt) (0. and then stop it. EWA13040 Before checking the coolant level. 15.Start the engine. WARNING G If coolant splashes in your eyes.22 Imp.Fill: G Cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Radiator capacity (including all routes) 0.Check: G Coolant level Refer to “CHECKING THE COOLANT LEVEL” on page 3-19. If water is used instead of coolant check. induce vomiting and get immediate medical attention. wait a few minutes until the coolant has settled. if distilled water is not available. immediately wash them with wa- G Adding 3-19 . ECA13480 CAUTION: water instead of coolant lowers the antifreeze content of the coolant.Install: G Radiator cap 12. quickly wash it away with water and then with soap and water. warm it up for several minutes.ENGINE 10. G If coolant splashes on your clothes. NOTE: Handling notes for coolant Coolant is potentially harmful and should be handled with special care.qt) Coolant reservoir capacity (up to the maximum level mark) 0. G Use only distilled water.79 Imp. G If coolant is swallowed. However. G If coolant comes into contact with painted surfaces.Install: G Air scoop (left/right) G Seat Refer to “GENERAL CHASSIS” on page 4-1. soft water may be used. thoroughly wash them with water and consult a doctor. 11.Fill: G Coolant reservoir (with the recommended coolant to the maximum level mark “a”) a 13.90 L (0.26 US qt) (0.25 L (0. G Do not mix different types of antifreeze.

Air in the brake system will consid- c. Loosen the locknut “1”. Turn the adjusting bolt “2” in direction “a” or “b” until the specified brake pedal position is obtained. Check: G Brake pedal position “a” (distance “a” from the top of the rider footrest to the top of the brake pedal) Out of specification → Adjust. 3-20 . ECA13490 CAUTION: ADJUSTING THE FRONT DISC BRAKE 1. Tighten the locknut “1”. b. Direction “a” Brake pedal is raised.5 mm (0. Direction “b” Brake lever free play is decreased. 2. Brake pedal position 11.0–8. make sure there is no brake drag.45 in) Front brake lever free play 5. b. c. Adjust: G Brake pedal position a MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Adjust: G Brake lever free play MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.20–0. the air must be removed by bleeding the brake system.0 mm (0. Direction “a” Brake lever free play is increased. Loosen the locknut “1”. Tighten the locknut “1” to specification.31 in) 2. Check: G Brake lever free play “a” Out of specification → Adjust. a After adjusting the brake lever position.CHASSIS EAS21140 CHASSIS EAS21170 erably reduce braking performance. Direction “b” Brake pedal is lowered. Turn the adjusting bolt “2” in direction “a” or “b” until the specified brake lever free play is obtained. a b 2 EWA13050 1 b 2 1 a WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21200 ADJUSTING THE REAR DISC BRAKE 1. Before the vehicle is operated.

Check: G Front brake pad Wear indicator groove “1” almost disappeard → Replace the brake pads as a set. WARNING R. G In order to ensure a correct reading of the brake fluid level. Operate the brake. always clean up any spilt brake fluid immediately. Adjust: G Rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” on page 3-24. 2. Therefore. leading to poor brake performance. NOTE: G Place the vehicle on a suitable stand. ECA13540 G Use CAUTION: Brake fluid may damage painted surfaces and plastic parts. Stand the vehicle on a level surface. Mixing brake fluids may result in a harmful chemical reaction. 8. Rear brake EWA13090 WARNING only the designated brake fluid. 1. be careful that water does not enter the brake fluid reservoir. 1 a 1 3-21 . make sure there is no brake drag. make sure the top of the brake fluid reservoir is horizontal. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3. G Make sure the vehicle is upright. Air in the brake system will considerably reduce braking performance. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. the air must be removed by bleeding the brake system.2 m•kg. Refer to “FRONT BRAKE” on page 4-11. ECA13510 CAUTION: After adjusting the brake pedal position. Before the vehicle is operated.7 ft•lb) B EWA13050 A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. G When refilling.CHASSIS Locknut 12 Nm (1. a A. EAS21240 CHECKING THE BRAKE FLUID LEVEL 1. Check: G Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. 2. causing leakage and poor brake performance. Front brake B. Other brake fluids may cause the rubber seals to deteriorate. Recommended fluid DOT 4 A T. G Refill with the same type of brake fluid that is already in the system.

Operate the brake. Hold the vehicle upright and apply the front brake several times. Check: G Rear brake light operation timing Incorrect → Adjust. Check: G Rear brake pad Wear indicators “1” almost touch the brake disc → Replace the brake pads as a set. Direction “b” Brake light comes on later. 3. 3-22 . Hold the main body “1” of the rear brake light switch so that it does not turn the adjusting nut “2” in direction “a” or “b” until the rear brake light comes on at the proper time. Check: G Brake hose Brake fluid leakage → Replace the damaged hose. Refer to “REAR BRAKE” on page 4-23. 4. 1 1 EAS21270 2. 2. EAS21290 a. EAS21330 CHECKING THE FRONT BRAKE HOSE 1. Refer to “FRONT BRAKE” on page 4-11. Adjust: G Rear brake light operation timing MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM 1 2. Check: G Brake hose “1” Cracks/damage/wear → Replace. Hold the vehicle upright and apply the rear brake several times. Check: G Brake hose “1” Cracks/damage/wear → Replace.CHASSIS EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 2. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. Check: G Brake hose “1” Brake fluid leakage → Replace the damaged hose. Check: G Brake hose clamp Loose Connection → Tighten the clamp bolt. Refer to “REAR BRAKE” on page 4-23. Check: G Brake hose clamp Loose Connection → Tighten the clamp bolt. Direction “a” Brake light comes on sooner. 4. 1. 1. 3. CHECKING THE REAR BRAKE HOSE 1. ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal.

c. g. b. Bleed: G Hydraulic brake system MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM G Be d. Slowly apply the brake several times. Place the other end of the hose into a container.6 m•kg. G a brake hose is loosened. Tighten the bleed screw and then release the brake lever or brake pedal. G the brake fluid level is very low. Connect a clear plastic hose “1” tightly to the bleed screw “2”. G When bleeding the hydraulic brake system. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. Remove: G Brake master cylinder reservoir cap NOTE: careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.3 ft•lb) a. considerably lengthening the bleeding procedure. e.CHASSIS A 2 1 B LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21350 2 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 1 WARNING Bleed the hydraulic brake system whenever: system is disassembled. Tighten the bleed screw to specification. h. 3-23 . Bleed screw 6 Nm (0. j. NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. EWA13110 After bleeding the hydraulic brake system. make sure there is always enough brake fluid before applying the brake. T. f. Fully pull the brake lever or fully press down the brake pedal and hold it in position. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-23. it may be necessary to let the brake fluid settle for a few hours. Rear 1. Loosen the bleed screw. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. 4. disconnected or replaced. Ignoring this precaution could allow air to enter the hydraulic brake system. G the A. k. check the brake operation. G If bleeding is difficult. Front B. i. and place an oil pan under the vinyl hose end on one side. WARNING R. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. G brake operation is faulty. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). 2.

Wheel axle nut 125 Nm (12. Direction “b” Drive chain is loosened. a T. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Stand the vehicle on a level surface. keep the drive chain slack within the specified limits. NOTE: 1 32 NOTE: G To Measure the drive chain slack in an intermediate position between the chain tensioner and the chain support bolt.0–48. it will wear out quickly. The drive chain slack must be checked at the tightest point on the chain. adjust both sides evenly.0 mm WR250X 40.6 m•kg. 3. especially when the T. Therefore. the drive chain should be serviced. ECA13550 CAUTION: A drive chain that is too tight will overload the engine and other vital parts. Therefore.5 m•kg. NOTE: b a Place the vehicle on a suitable stand so that the rear wheel is elevated. 3-24 . c. Check: G Drive chain slack “a” Out of specification → Adjust.0–50. Spin the rear wheel several times and find the tightest position of drive chain. Drive chain slack WR250R 38.0 mm 4. 2. and one that is too loose can skip and damage the swingarm or cause an accident. G Push the rear wheel forward to make sure there is no clearance between the swingarm end plates and the ends of the swingarm. d. Loosen both locknuts “2”. 1. If the drive chain is not maintained properly. Direction “a” Drive chain is tightened. Tighten the locknut.CHASSIS MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21420 ADJUSTING THE DRIVE CHAIN SLACK NOTE: a. 90 ft•lb) R. Tighten the wheel axle nut. 12 ft•lb) e. b. Loosen the wheel axle nut “1”. Adjust: G Drive chain slack LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21440 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. maintain the proper wheel alignment. Locknut 16 Nm (1. R. Turn the drive chain puller “3” in direction “a” or “b” until the specified drive chain slack is obtained.

If necessary. certain solvents. Install the rubber washer. and the use of a coarse brush can damage these O-rings. remove the lower bracket and inspect the upper and lower bearings. Check: G Steering head Grasp the bottom of the front fork legs and gently rock the front fork. and the rubber washer “3”. This vehicle has a drive chain with small rubber O-rings between each side plate. EWA13120 4 WARNING Securely support the vehicle so that there is no danger of it falling over. 4. EWA13140 T. use only kerosene to clean the drive chain. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains EAS21510 b. a. d. Loosen the lower ring nut “4” fully turn and then tighten it to specification with a steering nut wrench. 2. Therefore.1 ft•lb) e. Blinding/looseness → Adjust the steering head. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. R. 3.CHASSIS vehicle is used in dusty areas. Stand the vehicle on a level surface. Remove the lock washer “1”. 27 ft•lb) c. T. Finger tighten the upper ring nut “2”. Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O-rings. f. 5. 5 CHECKING AND ADJUSTING THE STEERING HEAD 1. Steam cleaning. 3-25 .8 m•kg. high-pressure washing. Lower ring nut (final tightening torque) 7 Nm (0. If it does not turn smoothly. Refer to “STEERING HEAD” on page 4-49. G Upper bracket Refer to “STEERING HEAD” on page 4-49. then align the slots of both ring nuts. WARNING Do not overtighten the lower ring nut. Turn the front fork to the right and left a few times. Install the upper ring nut. g. Tighten the lower ring nut “4” with a steering nut wrench “5”. and make sure that the steering rotates smoothly. Remove: G Handlebar Refer to “HANDLEBAR” on page 4-34.7 m•kg. Adjust: G Steering head MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Steering nut wrench 90890-01403 Spanner wrench YU-33975 Lower ring nut (initial tightening torque) 38 Nm (3. the upper ring nut “2”. R.

2. Rebound damping Maximum (hard) 1click(s) out* Standard 10 click(s) out* Minimum (soft) 12 click(s) out* * With the adjusting screw fully turned in 3-26 . Stand the vehicle on a level surface. NOTE: Make sure the special washer tabs “a” sit correctly in the ring nut slots “b”. Refer to “FRONT FORK” on page 4-39. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Hold the vehicle upright and apply the front brake. 3. Install: G Upper bracket Refer to “STEERING HEAD” on page 4-49. Direction “a” Rebound damping is increased (suspension is harder). 4. Rebound damping ECA13590 G Always CAUTION: Never go beyond the maximum or minimum adjustment positions. If this is not done. G Oil seal Oil leakage → Replace. Turn the adjusting screw “1” in direction “a” or “b”. EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.CHASSIS hold the lower ring nut and tighten the upper ring nut until their slots are aligned. Direction “b” Rebound damping is decreased (suspension is softer). Check: G Inner tube Damage/scratches → Replace. Rough movement → Repair. 1. the vehicle will have poor stability. EWA32D1006 WARNING LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 5. G Handlebar Refer to “HANDLEBAR” on page 4-34. a. Check: G Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. G Securely support the vehicle so that there is no danger of it falling over. Adjust: G Rebound damping MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM CHECKING THE FRONT FORK 1. EAS21530 adjust the left and right front forks evenly.

Bleed the air from the front fork. 1. Adjust: G Compression damping MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM CAUTION: a. Direction “a” Compression damping is increased (suspension is harder). 2.15 m•kg. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. b 1 WARNING R. G 1 3. Bleed the air from the front fork by removing bleed screw “1”. Stand the vehicle on a level surface. Compression damping Maximum (hard) 1 click(s) out* Standard 10 click(s) out* Minimum (soft) 19 click(s) out* * With the adjusting screw fully turned in Always bleed the left and right front fork evenly. Bleed following procedure. 1. Adjust: G Spring preload NOTE: AIR BLEEDING FROM FRONT FORK When the temperature increases in the front fork Remove the rear shock absorber from the vehi- 3-27 . a Securely support the vehicle so that there is no danger of it falling over. NOTE: LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Compression damping ECA13590 Stand the vehicle vertically using an appropriate stand.1 ft•lb) EAS21610 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EWA13120 T. 1. G If this is not done. Turn the adjusting screw “1” in direction “a” or “b”.CHASSIS a b 1 during touring. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS32D1020 1. Spring preload ECA13590 CAUTION: Never go beyond the maximum or minimum adjustment positions.5 Nm (0. the air pressure increases in the fork and the suspension will become less flexible. ECA32D1001 CAUTION: Never go beyond the maximum or minimum adjustment positions. the vehicle will have poor stability. and bleed the air from the front fork. Install: G Bleed screw Bleed screw 1. Direction “b” Compression damping is decreased (suspension is softer).

1. c. Adjust: G Compression damping 3-28 .5 mm (8. 30 ft•lb) T. Turn the adjusting knob “1” in direction “a” or “b”. Refer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-53. Direction “a” Spring preload is increased (suspension is harder). Loosen the locknut “1”. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Locknut 42 Nm (4.CHASSIS cle before this adjustment. Rebound damping Maximum (hard) 3 click(s) out* Standard 12 click(s) out* (WR250R) 13 click(s) out* (WR250X) Minimum (soft) 25 click(s) out* * With the adjusting knob fully turned in 1 2 a b Spring length “c” Standard 211. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Rebound damping ECA13590 CAUTION: Never go beyond the maximum or minimum adjustment positions. d. R. Turn the adjusting nut “2” in direction “a” or “b”. Adjust: G Rebound damping MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. a.11 in) Maximum (soft) 216 mm (8.2 m•kg.50 in) 1 b a c LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Compression damping ECA13590 CAUTION: Never go beyond the maximum or minimum adjustment positions. Tighten the locknut. Ring nut wrench 90890-01268 Spanner wrench YU-01268 b. 1. Direction “a” Rebound damping is increased (suspension is harder). Adjust the spring preload with a ring nut wrench. Direction “b” Rebound damping is decreased (suspension is softer).33 in) Minimum (hard) 206 mm (8. Direction “b” Spring preload is decreased (suspension is softer).

Check: G Tire surfaces Damage/wear → Replace the tire.00 kgf/cm2) Loading condition 90–185 kg (198–408 lb) Front WR250R 150 kPa (22 psi) (1.00 kgf/cm2) Rear WR250R 175 kPa (25 psi) (1. G Operation of an overloaded vehicle could cause tire damage. When the tire tread reaches the wear limit.25 kgf/cm2) WR250X 200 kPa (29 psi) (2. NEVER OVERLOAD THE VEHICLE. Loading condition 0–90 (0–198 lb) Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front WR250R 125 kPa (18 psi) (1.00 kgf/cm2) WR250X 225 kPa (33 psi) (2. replace the tire immediately. G The a b 1 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires.75 kgf/cm2) WR250X 200 kPa (29 psi) (2. 1. Compression damping Maximum (hard) 1 click(s) out* Standard 10 click(s) out* (WR250R) 7 click(s) out* (WR250X) Minimum (soft) 12 click(s) out* * With the adjusting screw fully turned in equals the ambient air temperature. cargo and accessories EWA13190 WARNING It is dangerous to ride with a worn-out tire.50 kgf/cm2) WR250X 200 kPa (29 psi) (2.00 kgf/cm2) Rear WR250R 200 kPa (29 psi) (2. passenger. 2. passenger and accessories) and the anticipated riding speed. EWA13180 WARNING G The tire pressure should only be checked and regulated when the tire temperature 3-29 . Check: G Tire pressure Out of specification → Regulate.25 kgf/cm2) Maximum load 185 kg (408 lb) * Total weight of rider. Direction “a” Compression damping is increased (suspension is harder). rider. Turn the adjusting screw “1” in direction “a” or “b”. an accident or an injury. Direction “b” Compression damping is decreased (suspension is softer). tire pressure and the suspension must be adjusted according to the total weight (including cargo.CHASSIS MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.

use great care and replace the tube as soon as possible with a good quality replacement. G Always replace a new tube tire and a new tube as a set. The front and rear tires should always be by the same manufacturer and of the same design. G When using a tube tire. G Align the mark “2” with the valve installation point. Front tire Size WR250R 80/100-21M/C 51P WR250X 110/70R17M/C 54H Manufacturer/model WR250R BRIDGESTONE/ TW-301 F WR250X BRIDGESTONE/ BT090F RADIAL G Rear tire Size WR250R 120/80-18M/C 62P WR250X 140/70R17M/C 66H Manufacturer/model WR250R BRIDGESTONE/ TW-302 F WR250X BRIDGESTONE/ BT090R RADIAL G EWA13210 Wear limit (front) 0.8 mm (0. the tires listed below have been approved by Yamaha Motor Co. A. Tubeless wheel G For 3-30 .03 in) EWA14080 WARNING not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. Wear indicator After extensive tests. Tire tread depth 2.CHASSIS Tube wheel Tube tire only Tube or tubeless tire 1 Tubeless wheel EWA14090 WARNING 2 3 1. Tube wheel B.8 mm (0. for this model. NOTE: tires with a direction of rotation mark “1”: Install the tire with the mark pointing in the direction of wheel rotation. Ltd. If it is absolutely necessary to do so.03 in) Wear limit (rear) 0. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehicle. Therefore. be sure to install the correct tube. G To avoid pinching the tube. make sure the wheel rim band and tube are centered in the wheel groove. A B G Do WARNING New tires have a relatively low grip on the road surface until they have been slightly worn. G Patching a punctured tube is not recommended.. approximately 100 km should be traveled at normal speed before any high-speed riding is done. Side wall 3.

Recommended lubricant Engine oil or a suitable cable lubricant NOTE: NOTE: A tight spoke will emit a clear. Tighten: (front/rear) G Spoke (with a spoke nipple wrench “1”) Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device.CHASSIS 1 2 1 EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels. 2. Check: G Wheel Damage/out-of-round → Replace.2 ft•lb) T. 3-31 . Tap the spokes with a screwdriver. a loose spoke will sound flat. 2. Check: G Outer cable Damage → Replace. NOTE: Be sure to tighten the spokes before and after break-in. 1. WARNING NOTE: Never attempt to make any repairs to the wheel. EWA13270 WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. 1. EAS21690 After a tire or wheel has been changed or replaced. R. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. Check: G Spoke Bends/damage → Replace. ringing tone. CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables.3 m•kg. always balance the wheel. EAS21680 CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. Replace damaged outer cable and inner cables as soon as possible. 2. Check: G Cable operation Rough movement → Lubricate. 1. Loose → Tighten. EWA13260 Spoke nipple wrench (8–9) 90890-01522 YM-01522 Spoke (front/rear) 3 Nm (0.

Recommented lubricant Lithium-soap-based grease 3-32 .CHASSIS Brake lever Silicone grease Clutch lever Lithium-soap-based grease EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. Recommended lubricant Lithium-soap-based grease EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand.

keep flammable products and your hands away from the bulb until it has cooled down. 1.7 m•kg. Install: G Headlight bulb New Fasten the new headlight bulb with the headlight bulb holder. EAS21780 REPLACING THE HEADLIGHT BULB EWA13320 WARNING 4. Remove: G Headlight coupler “1” G Bulb cover “2” 1 2 EAS21800 ADJUSTING THE HEADLIGHT BEAM 1. otherwise the transparency of the glass. 5.1 ft•lb) T. lift and remove the headlight unit from front fender grommet “2”. thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. R. If the headlight bulb gets soiled. Remove: G Headlight bulb holder “1” G Headlight bulb “2” 3-33 . Direction “a” Headlight beam is raised. 1 1 Avoid touching the glass part of the headlight bulb to keep it free from oil. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 8-59. Direction “b” Headlight beam is lowered. 5. Install: G Headlight bulb holder G Bulb cover G Headlight coupler 6. 2 3.ELECTRICAL SYSTEM EAS21750 ELECTRICAL SYSTEM EAS21760 2 1 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 8-59. Turn the adjusting screw “1” in direction “a” or “b”. Remove: G Headlight unit bolt “1” NOTE: CAUTION: After you have removed the headlight unit bolts. Adjust: G Headlight beam (vertically) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. the life of the bulb and the luminous flux will be adversely affected. 2 2. Install: G Headlight unit Headlight unit bolt 7 Nm (0. ECA13690 Since the headlight bulb gets extremely hot.

ELECTRICAL SYSTEM b a b a LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3-34 .

ELECTRICAL SYSTEM 3-35 .

ELECTRICAL SYSTEM 3-36 .

...............................................................................4-2 REMOVING THE FRONT WHEEL .................................................4-4 CHECKING THE FRONT WHEEL ........................................................................................................................4-19 INSTALLING THE FRONT BRAKE CALIPER ................................................4-21 REAR BRAKE..4-20 CHECKING THE FRONT BRAKE MASTER CYLINDER .............................4-32 HANDLEBAR ..........................4-18 DISASSEMBLING THE FRONT BRAKE CALIPER.....4-36 1 2 3 4 5 6 7 8 9 ......................................................................................................................................4-31 CHECKING THE REAR BRAKE MASTER CYLINDER............................................................................4-20 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...........4-10 FRONT BRAKE...................4-28 REPLACING THE REAR BRAKE PADS .4-34 REMOVING THE HANDLEBARS ........4-16 CHECKING THE FRONT BRAKE DISC ......4-9 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ...........................................4-10 INSTALLING THE REAR WHEEL (DISC) .........4-32 INSTALLING THE REAR BRAKE MASTER CYLINDER...........................................................4-9 ASSEMBLING THE REAR WHEEL ........................4-28 REMOVING THE REAR BRAKE CALIPER .......................4-28 CHECKING THE REAR BRAKE DISC ..........................4-9 DISASSEMBLING THE REAR WHEEL ..4-5 REAR WHEEL.......................................................................4-29 CHECKING THE REAR BRAKE CALIPER..................................................................................4-36 INSTALLING THE HANDLEBAR ........................................................................CHASSIS GENERAL CHASSIS ..................4-1 FRONT WHEEL ......................................................................4-21 INSTALLING THE FRONT BRAKE MASTER CYLINDER ......................................................4-36 CHECKING THE HANDLEBAR .....4-30 REMOVING THE REAR BRAKE MASTER CYLINDER ..............................................4-19 REMOVING THE FRONT BRAKE MASTER CYLINDER......................................................................................................................4-16 REPLACING THE FRONT BRAKE PADS ............................................................................4-18 ASSEMBLING THE FRONT BRAKE CALIPER...................................................4-9 CHECKING THE REAR WHEEL .4-17 REMOVING THE FRONT BRAKE CALIPER........................................4-11 INTRODUCTION...............................4-4 DISASSEMBLING THE FRONT WHEEL.....................................................4-7 REMOVING THE REAR WHEEL.........................................................................................................................................4-18 CHECKING THE FRONT BRAKE CALIPER ............4-31 ASSEMBLING THE REAR BRAKE MASTER CYLINDER .......................................................................4-5 INSTALLING THE FRONT WHEEL (DISC) ....................4-29 DISASSEMBLING THE REAR BRAKE CALIPER ..................................................................................4-23 INTRODUCTION.................................................4-30 ASSEMBLING THE REAR BRAKE CALIPER ......................................................................................................................................................................................................................4-30 INSTALLING THE REAR BRAKE CALIPER......................................................................4-5 ASSEMBLING THE FRONT WHEEL...........................

.......4-55 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ..............................................................................................4-43 INSTALLING THE FRONT FORK LEGS ..........................................................................................4-57 INSTALLING THE SWINGARM ........................................4-42 DISASSEMBLING THE FRONT FORK LEGS..4-55 SWINGARM ..................................4-60 CHECKING THE DRIVE SPROCKET .................................................................................................................................................................4-42 CHECKING THE FRONT FORK LEGS .........................................................................................4-51 INSTALLING THE STEERING HEAD...............4-56 REMOVING THE SWINGARM ........................................................4-61 INSTALLING THE DRIVE CHAIN .................4-54 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ...4-47 STEERING HEAD ..4-60 CHECKING THE DRIVE CHAIN ...............................................4-43 ASSEMBLING THE FRONT FORK LEGS.................................................................................................................4-51 CHECKING THE STEERING HEAD.....................................................................................4-61 CHECKING THE REAR WHEEL SPROCKET.........................................................................................4-49 REMOVING THE LOWER BRACKET .........................................................................................FRONT FORK ............4-54 INSTALLING THE RELAY ARM ..................................4-51 REAR SHOCK ABSORBER ASSEMBLY ......................................4-53 HANDLING THE REAR SHOCK ABSORBER.........................................................................................................................4-57 CHECKING THE SWINGARM ....4-61 .............................................................4-39 REMOVING THE FRONT FORK LEGS.4-54 DISPOSING OF A REAR SHOCK ABSORBER ........................4-57 CHAIN DRIVE .....................................................4-54 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ......................................................................................4-59 REMOVING THE DRIVE CHAIN ..............................................4-54 CHECKING THE CONNECTING ARM AND RELAY ARM.............

0 m • kg. 5 10 Nm (1.2 ft • Ib) T. 6 T. 7.7 m • kg. Job/Parts to remove Seat Left side cover Right side cover Left air panel Left air scoop Right air panel Right air scoop Q’ty 1 1 1 1 1 1 1 Remarks For installation. R. R. 1 7 2 Order 1 2 3 4 5 6 7 R. 4-1 . R.7 m • kg. 4 T. reverse the removal procedure. 5. 5.1 ft • Ib) 3 T.1 ft • Ib) 4 Nm (0. 7 Nm (0. 7 Nm (0. 2.1 ft • Ib) R.9 ft • Ib) T. 5.7 m • kg.4 m • kg.GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the cowling 7 Nm (0.

8 R.7 ft • Ib) (WR250R) 23 Nm (2. R. R. 17 ft • Ib) (WR250X) T. 1 2 3 4 5 6 7 8 9 Front wheel axle pinch bolt Front wheel axle nut Front wheel axle Cap Front wheel assembly Collar Collar Front brake disc Wheel ring 4 1 1 1 1 1 1 1 1 For Europe Only WR250R For installation. reverse the removal procedure. 7 (6) (6) LT T.2 m • kg. 5 9 63 Nm (6. Order Job/Parts to remove Q’ty Remarks Use a suitable stand to raise the front wheel off the ground. 4-2 . 4 R. 17 ft • Ib) T. 3 (4)1 2 6 23 Nm (2. Loosen. 17 ft • Ib) T. 8.3 m • kg. R.3 m • kg.3 m • kg. 12 Nm (1.FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 23 Nm (2. 46 ft • Ib) T.3 m • kg.

FRONT WHEEL Disassembling the front wheel 1 2 3 2 1 Order 1 2 3 Oil seal Bearing Spacer Job/Parts to remove Q’ty 2 2 1 Remarks For assembly. 4-3 . reverse the disassembly procedure.

0 mm (0. ringing tone. 2. R. 3. 2.08 in) 6. Check: G Spokes Bends/damage → Replace. Tap the spokes with a screwdriver. EAS21930 CHECKING THE FRONT WHEEL 1. Check: G Collars Damage/wear → Replace. 2. Refer to “CHECKING THE TIRES” on page 1-31 and “CHECKING THE WHEELS” on page 1-33. 5. G Oil seals Damage/wear → Replace.FRONT WHEEL EAS21890 REMOVING THE FRONT WHEEL 1. T. Loose → Tighten.0 mm (0. measure the front wheel runout. Radial wheel runout limit 2. Bends → Replace. Check: G Tire G Front wheel Damage/wear → Replace. Remove: G Front wheel NOTE: NOTE: A tight spoke will emit a clear. Tighten: G Spokes Refer to “CHECKING AND TIGHTENING THE SPOKES” on page 1-33.08 in) Lateral wheel runout limit 2. Stand the vehicle on a level surface. Measure: G Front wheel radial runout “a” G Front wheel lateral runout “b” Over the specified limits → Replace. b a EWA13460 WARNING Do not attempt to straighten a bent wheel axle. 7. Check: G Wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings. a loose spoke will sound flat.2 ft•lb) Place the vehicle on a suitable stand so that the front wheel is elevated.3 m•kg. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. NOTE: After tightening the spokes. 4-4 . EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Spoke 3 Nm (0. Check: G Wheel axle Roll the wheel axle on a flat surface. 4.

INSTALLING THE FRONT WHEEL (DISC) The following procedure applies to both of the brake discs. Install the new wheel bearings and oil seals in the reverse order of disassembly. Lubricate: G Wheel axle G Oil seal lips Recommended lubricant Lithium-soap-based grease 2. 1 a. Tighten: G Wheel axle nut “1” G Wheel axle pinch bolt ECA14140 CAUTION: Before tightening the wheel axle nut.3 m•kg. Clean the outside of the front wheel hub. Contact should be made only with the outer race. NOTE: EAS21910 DISASSEMBLING THE FRONT WHEEL 1. Remove: G Oil seals G Wheel bearings MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Use a socket “1” that matches the diameter of the wheel bearing outer race and oil seal.3 m•kg. 1. ECA14130 CAUTION: Do not contact the wheel bearing inner race or balls. Install: G Wheel bearings 4-5 . push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly. R. b. Remove the wheel bearings with a general bearing puller. ASSEMBLING THE FRONT WHEEL 1. NOTE: To prevent damaging the wheel. 2 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS22000 1 c.FRONT WHEEL G Oil seals New MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Wheel axle nut 63 Nm (6. Remove the oil seals “1” with a flat-head screwdriver. place a rag “2” between the screwdriver and the wheel surface. 17 ft•lb) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21960 T. 46 ft•lb) Wheel axle pinch bolt 23 Nm (2.

FRONT WHEEL

1

4-6

REAR WHEEL
EAS22020

REAR WHEEL
Removing the rear wheel
125 Nm (12.5 m • kg, 90 ft • Ib)

4

6 8 9

Order

T.

R.

1 (6)

LT

12 Nm (1.2 m • kg, 8.7 ft • Ib)

10 (6) 7

T.

R.

(6)
35 Nm (3.5 m • kg, 25 ft • Ib)
T.

R.

2 4 5
T.

3
16 Nm (1.6 m • kg, 12 ft • Ib)
R.

Job/Parts to remove

Q’ty

Remarks Use a suitable stand to raise the front wheel off the ground.

1 2 3 4 5 6 7 8 9 10

Rear wheel axle nut Locknut Rear wheel axle Chain puller (left/right) Drive chain Rear wheel assembly Collar left/Dust cover Collar right/Dust cover Rear brake disc Rear wheel sprocket

1 2 1 1/1 1 1 1/1 1/1 1 1 For installation, reverse the removal procedure. It loosens and adjusting bolt is tightened fully.

4-7

REAR WHEEL
Disassembling the rear wheel

1 2 3

2 1

Order 1 2 3

Job/Parts to remove Oil seal (left/right) Bearing (left/right) Spacer

Q’ty 1/1 1/1 1

Remarks

For assembly, reverse the disassembly procedure.

4-8

REAR WHEEL
EAS22040

REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface.
EWA13120

WARNING

Securely support the vehicle so that there is no danger of it falling over.
NOTE:

Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Elevate: G Rear wheel 3. Remove: G Rear wheel axle nut “1” 4. Loosen: G Locknut 5. Tighten: G Adjusting bolt
NOTE:

Oil seals Refer to “CHECKING THE FRONT WHEEL” on page 4-4. 2. Check: G Tire G Rear wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” on page 1-31 and “CHECKING THE WHEELS” on page 1-33. 3. Check: G Spokes Refer to “CHECKING THE FRONT WHEEL” on page 4-4. 4. Measure: G Radial wheel runout G Lateral wheel runout Refer to “CHECKING THE FRONT WHEEL” on page 4-4.
G

Place the motorcycle on a suitable stand so that the rear wheel is elevated. 6. Remove: G Wheel axle “2” G Rear wheel “3”

Radial wheel runout limit 2.0 mm Lateral wheel runout limit 2.0 mm
EAS22120

3 1 2

CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: G Rear wheel sprocket More than 1/4 tooth wear → Replace the rear wheel sprocket. Bent teeth → Replace the rear wheel sprocket. 1

NOTE:

a 2 b

Push the rear wheel forward and remove the drive chain from the rear wheel sprocket.
EAS22080

DISASSEMBLING THE REAR WHEEL 1. Remove: G Oil seals G Wheel bearings Refer to “DISASSEMBLING THE FRONT WHEEL” on page 4-5.
EAS22100

a. Tooth face b. Normal 1. Drive chain roller 2. Rear wheel sprocket

CHECKING THE REAR WHEEL 1. Check: G Wheel axle G Rear wheel G Wheel bearings

2. Replace: G Rear wheel sprocket
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

a. Remove the self-locking nuts and the rear wheel sprocket.

4-9

REAR WHEEL
b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c. Install the new rear wheel sprocket. Rear wheel sprocket self-locking nut 35 Nm (3.5 m•kg, 25 ft•lb) Drive chain slack WR250R 38.0–48.0 mm (1.50–1.89 in) WR250X 40.0–50.0 mm (1.57–1.97 in) 4. Tighten: G Wheel axle nut Wheel axle nut 125 Nm (12.5 m•kg, 90 ft•lb)

NOTE:

Tighten the self-locking nuts in stages and in a crisscross pattern.

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL
EAS22140

ASSEMBLING THE REAR WHEEL 1. Install: G Wheel bearings G Oil seals New Refer to “ASSEMBLING THE FRONT WHEEL” on page 4-5.
EAS22160

INSTALLING THE REAR WHEEL (DISC) 1. Install: G Brake disc Refer to “CHECKING THE REAR BRAKE DISC” on page 4-28 2. Lubricate: G Wheel axle G Oil seal lips Recommended lubricant Lithium-soap-based grease 3. Adjust: G Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 1-26.

T.

R.

T.

R.

4-10

FRONT BRAKE
EAS22210

FRONT BRAKE
Removing the front brake pads

23 Nm (2.3 m • kg, 17 ft • Ib) 17 Nm (1.7 m • kg, 12 ft • Ib)

T.

R.

T.

R.

3
S

5 2
S
17 Nm (1.7 m • kg, 12 ft • Ib)
T.

2 1

R.

WR250X Order 1 2 3 4 5 Job/Parts to remove Pin plug Front brake caliper support bolt Front brake caliper assembly Brake pad Brake pad spring

4
Q’ty 1 1 1 2 2

2.5 Nm (0.25 m • kg, 1.8 ft • Ib)

WR250X only

For installation, reverse the removal procedure.

T.

R.

Remarks

4-11

FRONT BRAKE
Removing the front brake master cylinder
4 Nm (0.4 m • kg, 2.9 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.

R.

T.

R.

1

7 10 8 9

4 Nm (0.4 m • kg, 2.9 ft • Ib)

Order Brake fluid 1 2 3 4 5 6 7 8 9 10 11

T.

R.
T.

S

11

2

S

3
S

5 6 4
30 Nm (3.0 m • kg, 22 ft • Ib)
R.

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.

R.

Job/Parts to remove

Q’ty

Remarks Drain. Refer to“BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25.

Rear view mirror (right) Brake lever Front brake switch Union bolt Copper washer Front brake hose Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Front brake master cylinder holder Front brake master cylinder

1 1 1 1 2 1 1 1 1 1 1 For installation, reverse the removal procedure.

4-12

reverse the disassembly procedure. 4-13 .FRONT BRAKE Disassembling the front brake master cylinder 1 Order 1 Job/Parts to remove Master cylinder kit Q’ty 1 Remarks For assembly.

22 ft • Ib) T.3 ft • Ib) T. 4.6 m • kg. 12 ft • Ib) 30 Nm (3.5 Nm (0. 4 10 1 2 9 8 6 S 17 Nm (1. 1. 10 Nm (1. R.3 m • kg. R. 3 S 6 5 R.2 ft • Ib) T. Order Brake fluid 1 2 3 4 5 6 7 8 9 10 Job/Parts to remove Remarks Drain.8 ft • Ib) T. R. WR250X 7 Q’ty R.FRONT BRAKE Removing the front brake calipers 17 Nm (1. T.0 m • kg. Brake hose holder Union bolt Copper washer Front brake hose Pin plug Front brake caliper support bolt Brake pad Brake pad spring Front brake caliper assembly Front brake caliper bracket 1 1 2 1 1 1 2 2 1 1 Only WR250X For installation. 4-14 . T.7 m • kg. R. Refer to“BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. 7. R.0 m • kg. reverse the removal procedure. 12 ft • Ib) 2.25 m • kg. 23 Nm (2. 17 ft • Ib) 6 Nm (0. T.7 m • kg.

6 m • kg. 4-15 .FRONT BRAKE Disassembling the front brake calipers 6 Nm (0. 4.3 ft • Ib) T. R. 1 2 3 S 4 BF S BF Order 1 2 3 4 Job/Parts to remove Brake caliper piston Brake caliper dust seal Brake caliper piston seal Bleed screw Q’ty 2 2 2 1 Remarks For assembly. reverse the disassembly procedure.

Hold the dial gauge at a right angle against the brake disc surface.12 in) WR250X 3. always follow these preventive measures: G Never disassemble brake components unless absolutely necessary. b. Adjust: G Brake disc deflection MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. d. Measure: G Brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. b. Before measuring the front brake disc deflection. Measure: G Brake disc thickness Measure the brake disc thickness at a few different locations. CHECKING THE FRONT BRAKE DISC 1.15 mm (0. drained. 2. Check: G Front brake disc Damage/galling → Replace. Turn the brake disc by one bolt hole. Therefore. Remove the brake disc. G Brake fluid may damage painted surfaces and plastic parts. properly filled. and bled after reassembly. Brake disc deflection limit 0. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. cleaned. G Never use solvents on internal brake components.39 in). Remove: G Front wheel Refer to “FRONT WHEEL” on page 4-2.14 in) 5. EAS22230 a. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4.5 mm (0. Remove the brake caliper. G If any connection on the hydraulic brake system is disconnected. Measure the deflection front 10 mm (0. Install the brake disc. the entire brake system must be disassembled. 3.28 in) below the edge of the brake disc. c.FRONT BRAKE EAS22220 INTRODUCTION EWA14100 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM WARNING Disc brake components rarely require disassembly.0059 in) 4-16 . Therefore.0 mm (0. G Use only clean or new brake fluid for cleaning brake components. e. Place the vehicle on a suitable stand so that the front wheel is elevated. G Avoid brake fluid coming into contact with the eyes as it can cause serious injury. Brake disc thickness limit WR250R 3. turn the handlebar to the left or right to ensure that the front wheel is stationary. Out of specification → Replace. c. always clean up any spilt brake fluid immediately. G FIRST AID FOR BRAKE FLUID ENTERING THE EYES: G Flush with water for 15 minutes and get immediate medical attention. rear 7 mm (0.

3 m•kg. Measure the brake disc deflection.3 m•kg. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. 4. Brake pad lining thickness (inner) WR250R 4.7 ft•lb) LOCTITE® WR250X:23 Nm (2.19 in) WR250X 4. Tighten the bleed screw.0 mm (0.04 in) T. Always install new brake pads. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 6.19 in) WR250X 4.0 mm (0. e. and a brake pad spring as a set. 2 1 b. T.FRONT BRAKE a LT Brake disc bolt WR250R:12 Nm (1.0 mm (0. R. Install new brake pads and a new brake pad spring. Install: G Brake pad pins G Brake pad clips G Brake pad cover G Brake caliper Brake caliper bolt 23 Nm (2.16 in) Limit 1.6 m•kg.8 mm (0. R. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. If the brake disc deflection cannot be brought within specification. replace the brake disc. c.0 mm (0. Measure: G Brake pad wear limit “a” Out of specification → Replace the brake pads as a set.8 mm (0. 17 ft•lb) T. Install: G Front wheel Refer to “FRONT WHEEL” on page 4-2.2 m•kg.04 in) Brake pad lining thickness (outer) WR250R 4. 4-17 . Bleed screw 6 Nm (0. 1. Connect a clear plastic hose “1” tightly to the bleed screw “2”. 17 ft•lb) LOCTITE® 2. If out of specification. R.16 in) Limit 1.3 ft•lb) d. Install: G Brake pads G Brake pad spring NOTE: d. 8. Put the other end of the hose into an open container. EAS22280 REPLACING THE FRONT BRAKE PADS NOTE: When replacing the brake pads. f. it is not necessary to disconnect the brake hose or disassemble the brake caliper. repeat the adjustment steps until the brake disc deflection is within specification. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3.

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS22380 Put the end of the brake hose into a container and pump out the brake fluid carefully. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 1-23. Remove the dust seals and brake caliper piston seals. drain the brake fluid from the entire brake system. 1 3 2 = MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. EAS22320 CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads Piston seals Brake hoses Brake fluid If necessary Every two years Every four years Every two years and whenever the brake is disassembled DISASSEMBLING THE FRONT BRAKE CALIPER 1. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. 4-18 . Remove: G Union bolt G Copper washers G Brake hose NOTE: b. Check: G Brake lever free play Refer to “ADJUSTING THE FRONT DISC BRAKE” on page 1-22. Remove: G Brake caliper pistons “1” G Brake caliper dust seals “2” G Brake caliper piston seals “3” 1. G Brake pedal operation Soft or spongy feeling → Bleed the brake system. Be careful not to get injured when the piston is expelled from the brake caliper. EWA13550 WARNING 5. 1. REMOVING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper. EAS22290 G Cover the brake caliper piston with a rag. G Never try to pry out the brake caliper piston. Check: G Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level.FRONT BRAKE 4. Check: G Brake caliper pistons “1” Rust/scratches/wear → Replace the brake caliper pistons. Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper.

2 3 CAUTION: When installing the brake hose onto the brake caliper “1”. 17 ft•lb) Brake hose union bolt 30 Nm (30. m•kg. Check: G Brake caliper bracket Cracks/damage → Replace. R.3 m•kg. Other brake fluids may cause the rubber seals to deteriorate. Refer to “CABLE ROUTING” on page 2-30. 2. WARNING R. 1 EWA13600 1 a b WARNING Whenever a brake caliper is disassembled. Install: G Front brake caliper bracket G Front brake caliper (temporarily) G Copper washers New G Brake hose G Union bolt WARNING G Use only the designated brake fluid. 22 ft•lb) EWA13530 Proper brake hose routing is essential to insure safe vehicle operation. G Whenever a brake caliper is disassembled. causing leakage and poor 4-19 . make sure the brake pipe “a” touches the projection “b” on the brake caliper. all internal brake components should be cleaned and lubricated with clean or new brake fluid. G Front brake caliper bracket 23 Nm (2. Recommended fluid DOT 4 EAS22420 G Before 2.FRONT BRAKE Brake caliper cylinders “2” Scratches/wear → Replace the brake caliper assembly. Install: G Front brake caliper G Brake pad springs G Front brake caliper support bolt G Brake hose holder Front brake caliper support bolt 17 Nm (1. EAS22400 1 ASSEMBLING THE FRONT BRAKE CALIPER EWA13620 WARNING installation.2 ft•lb) Refer to “REPLACING THE FRONT BRAKE PADS” on page 4-17. 7. 12 ft•lb) Brake hose holder 10 Nm (1. INSTALLING THE FRONT BRAKE CALIPER 1. replace the piston seals. replace the brake caliper piston seals. G Never use solvents on internal brake components as they will cause the piston seals to swell and distort. 3. G Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly.7 m•kg. G Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. ECA14170 T.0 m•kg. Fill: G Brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended fluid DOT 4 EWA13090 T.

Check: G Brake hoses Cracks/damage/wear → Replace. Check: G Brake master cylinder reservoir diaphragm holder G Brake master cylinder reservoir diaphragm holder Cracks/damage → Replace. EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1. Check: G Brake master cylinder reservoir cap 4. 3. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. G When refilling. be careful that water does not enter the brake fluid reservoir. 1 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: 2 2. 6. G Brake fluid delivery passages “2” (brake master cylinder body) Obstruction → Blow out with compressed air. Before removing the front brake master cylinder. drain the brake fluid from the entire brake system. always clean up any spilt brake fluid immediately. 5. Check: G Brake master cylinder kit Damage/scratches/wear → Replace. Disconnect: G Brake switch coupler “1” (from the brake master cylinder) 4-20 . Check: G Brake fluid level Below the minimum level mark → Add the recommended brake fluid to the proper level. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. G Brake lever operation Soft or spongy feeling → Bleed the brake system. Bleed: G Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. Mixing brake fluids may result in a harmful chemical reaction. 1. 4. Therefore. EAS22490 2. leading to poor brake performance. 5. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 1-23. Check: G Brake lever free play Refer to “ADJUSTING THE FRONT DISC BRAKE” on page 1-22. Check: G Brake master cylinder “1” Damage/scratches/wear → Replace. Remove: G Union bolt G Copper washers G Brake hoses NOTE: To collect any remaining brake fluid.FRONT BRAKE brake performance. place a container under the master cylinder and the end of the brake hose. with the same type of brake fluid that is already in the system. G Refill ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts.

Correct if necessary. NOTE: holding the brake hose. tighten the union bolt as shown.7 m•kg. cables. Install: G Circlip “1” New G Dust boot “2” New G G Before a 1 2. 2 3 3. G Never use solvents on internal brake components. Install: Master cylinder cup G Master cylinder piston 2. causing leakage and poor 4-21 .FRONT BRAKE EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER EWA13520 WARNING installation. leads). 5. Recommended fluid DOT 4 1. 22 ft•lb) EWA13530 Proper brake hose routing is essential to insure safe vehicle operation. G Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e. EAS22530 G While T. all internal brake components should be cleaned and lubricated with clean or new brake fluid. Fill: G Brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended fluid DOT 4 EWA13540 WARNING G Use only the designated brake fluid. Install: G Brake master cylinder “1” Brake master cylinder holder bolt 7 Nm (0. Install: G Copper washers “1” New G Brake hose “2” G Union bolt “3” Brake hose union bolt 30 Nm (30. R.1 ft•lb) 1 New NOTE: the brake master cylinder holder with the “UP” mark facing up. tighten the upper bolt. G Install T.. wire harness.g. Other brake fluids may cause the rubber seals to deteriorate. Refer to “CABLE ROUTING” on page 2-30. then the lower bolt. m•kg. INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. G First. G Align the end of the brake master cylinder holder with the punch mark “a” on the handlebar. WARNING R.

5. Check: G Brake fluid level Below the minimum level mark → Add the recommended brake fluid to the proper level. always clean up any spilt brake fluid immediately. Mixing brake fluids may result in a harmful chemical reaction. G Refill ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts. 6. be careful that water does not enter the brake master cylinder reservoir. 4-22 . with the same type of brake fluid that is already in the system. leading to poor brake performance. G Brake lever operation Soft or spongy feeling → Bleed the brake system. G When refilling. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. Check: G Brake lever free play Refer to “ADJUSTING THE FRONT DISC BRAKE” on page 1-22. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.FRONT BRAKE brake performance. 4. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 1-23. Bleed: G Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. Therefore.

For installation. 4-23 . 12 ft • Ib) 2. Order 1 2 3 4 5 6 7 8 Job/Parts to remove Rear wheel Protector Pin plug Brake pad support bolt Rear brake pad Pad shim Insulator Rear brake pad spring Rear brake caliper assembly Q’ty 1 1 1 2 2 2 1 1 Remarks Refer to“REAR WHEEL” on page 4-7. 2 5 6 1 7 6 5 4 7 Nm (0. R.7 m • kg. 3 R. R. T. 1. 5.REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 8 17 Nm (1. reverse the removal procedure.7 m • kg.5 Nm (0.25 m • kg.8 ft • Ib) T.1 ft • Ib) T.

Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. R. 30 Nm (3. 7 1 8 9 2 3 10 4 5 6 Order Brake fluid 1 2 3 4 5 6 7 8 9 10 Job/Parts to remove Q’ty Remarks Drain.0 m • kg. 4-24 .2 ft • Ib) T.REAR BRAKE Removing the rear brake master cylinder 10 Nm (1. 22 ft • Ib) T. reverse the removal procedure. 7. R. Union bolt Copper washer Brake hose Split pin Plain washer Pin Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder 1 2 1 1 1 1 1 1 1 1 For installation.0 m • kg.

2 m • kg.7 ft • Ib) T. 8.REAR BRAKE Disassembling the rear brake master cylinder 1 S 12 Nm (1. R. reverse the disassembly procedure. 4-25 . Order 1 Job/Parts to remove Master cylinder kit Q’ty 1 Remarks For assembly.

1 2 9 S 3 17 Nm (1. 4 2. 1 2 3 4 5 6 7 8 9 Protector Union bolt Copper washer Rear brake hose Pin plug Brake caliper support bolt Rear brake pad assemblyl Rear brake caliper bracket Brake pad spring Rear brake caliper assembly 1 2 1 1 1 2 1 2 1 For installation. R. 7 5 8 T. 6 Order Brake fluid Job/Parts to remove Q’ty Remarks Drain. 1.25 m • kg. Refer to“BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. Refer to“REAR BRAKE” on page 4-23.REAR BRAKE Removing the rear brake calipers 8 30 Nm (3.8 ft • Ib) R.0 m • kg. reverse the removal procedure.7 m • kg. 4-26 . 22 ft • Ib) T.5 Nm (0. 12 ft • Ib) T. R.

R. 4. 4-27 .3 ft • Ib) T.6 m • kg. Order 1 2 3 4 Job/Parts to remove Brake caliper piston Brake caliper dust seal Brake caliper piston seal Bleed screw Q’ty 1 1 1 1 Remarks For assembly.REAR BRAKE Disassembling the rear brake calipers 1 2 3 S BF 4 6 Nm (0. reverse the disassembly procedure.

Check: G Brake disc Damage/galling → Replace.7 ft•lb) LOCTITE® WARNING Disc brake components rarely require disassembly. Out of specification → Replace. Measure: G Brake pad wear limit “a” Out of specification → Replace the brake pads as a set.0 mm (0. Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-16.25 in) Limit 1. Install: G Rear wheel Refer to “REAR WHEEL” on page 4-7. CHECKING THE REAR BRAKE DISC 1. and bled after reassembly.0059 in) 4.16 in) 5.REAR BRAKE EAS22560 INTRODUCTION EWA14100 Brake disc thickness limit 4. Therefore. Measure: G Brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit 0. G Brake fluid may damage painted surfaces and plastic parts.4 mm (0. brake pad shims.04 in) Brake pad lining thickness (outer) 6. drained. properly filled. EAS22580 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads.4 mm (0. G FIRST AID FOR BRAKE FLUID ENTERING THE EYES: G Flush with water for 15 minutes and get immediate medical attention. Install: G Brake pad shims (onto the brake pads) G Brake pads G Brake pad spring NOTE: Always install new brake pads. 2. G Avoid brake fluid coming into contact with the eyes as it can cause serious injury. Remove: G Rear wheel Refer to “REAR WHEEL” on page 4-7. Brake disc bolt 12 Nm (1. G If any connection on the hydraulic brake system is disconnected. 8. R. 4-28 .04 in) T. EAS22570 6.25 in) Limit 1. Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-16. a 2. Therefore.0 mm (0. always follow these preventive measures: G Never disassemble brake components unless absolutely necessary. the entire brake system must be disassembled. 1. Brake pad lining thickness (inner) 6. it is not necessary to disconnect the brake hose or disassemble the brake caliper. G Use only clean or new brake fluid for cleaning brake components.15 mm (0. cleaned. 3. Adjust: G Brake disc deflection Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-16.2 m•kg.0 mm (0. G Never use solvents on internal brake components. always clean up any spilt brake fluid immediately. Measure: G Brake disc thickness Measure the brake disc thickness at a few different locations.

c.8 ft•lb) Rear brake caliper protector 7 Nm (0.7 m•kg. Tighten the bleed screw. Install new brake pads and a new brake pad spring. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 1-23. EAS22590 b. Bleed screw 6 Nm (0. 2 a 1 5. Install: G Brake caliper support bolt G Pin plug G Rear brake caliper protector Brake caliper support bolt 17 Nm (1. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. 4. e. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3. NOTE: The longer tangs “b” of the brake pad spring must point in the direction of disc rotation.7 m•kg. Remove: G Union bolt G Copper washers G Brake hose NOTE: d.3 ft•lb) REMOVING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper. EAS22600 DISASSEMBLING THE REAR BRAKE CALIPER 1. drain the brake fluid from the entire brake system. 4-29 . Check: G Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. 1 2 3 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. 12 ft•lb) Pin plug 2. Blow compressed air into the brake hose joint opening to force out the piston from the brake caliper. Check: G Brake pedal operation Soft or spongy feeling → Bleed the brake system. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. 1. T. 1. T. Install a new brake pad shim onto each new brake pad. Remove: G Brake caliper piston “1” G Brake caliper dust seals “2” G Brake caliper piston seals “3” R. Put the other end of the hose into an open container. R. 5. Connect a clear plastic hose “1” tightly to the bleed screw “2”.25 m•kg.REAR BRAKE and a brake pad spring as a set. Put the end of the brake hose into a container and pump out the brake fluid carefully.1 ft•lb) 4.6 m•kg.5 Nm (0. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.

replace the brake caliper piston seals. Recommended fluid DOT 4 EAS22670 G Before 1. INSTALLING THE REAR BRAKE CALIPER 1. Refer to “CA- T. Remove the brake caliper dust seals brake caliper piston seals. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS22640 EAS22650 ASSEMBLING THE REAR BRAKE CALIPER EWA13620 WARNING CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads Piston seals Brake hoses Brake fluid If necessary Every two years Every four years Every two years and whenever the brake is disassembled installation. G Whenever a brake caliper is disassembled.REAR BRAKE EWA13550 WARNING the brake caliper piston with a rag. replace the brake caliper piston seals. G Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. b. m•kg. all internal brake components should be cleaned and lubricated with clean or new brake fluid. G Brake caliper cylinders “2” Scratches/wear → Replace the brake caliper assembly. G Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. G Brake hose G Union bolt Union bolt 30 Nm (30. Check: G Brake caliper pistons “1” Rust/scratches/wear → Replace the brake caliper pistons. 2. 3 EWA13610 G Cover 2 1 WARNING Whenever a brake caliper is disassembled. Be careful not to get injured when the piston is expelled from the brake caliper. G Never use solvents on internal brake components as they will cause the piston seals to swell and distort. WARNING R. G Never try to pry out the brake caliper piston. 22 ft•lb) EWA13530 Proper brake hose routing is essential to insure safe vehicle operation. Check: G Brake caliper brackets Cracks/damage → Replace. Install: G Rear wheel Refer to “REAR WHEEL” on page 4-7. Install: G Rear brake caliper G Rear brake caliper bracket 2. 4-30 .

G When refilling. Bleed: G Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. Check: G Brake pedal operation Soft or spongy feeling → Bleed the brake system. Check: G Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. WARNING R. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Install: G Brake pad springs G Brake pads G Brake caliper support bolt G Pin plug Refer to “REPLACING THE REAR BRAKE PADS” on page 4-28. Brake caliper support bolt 17 Nm (1. G Refill with the same type of brake fluid that is already in the system. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 1-23. EAS22700 4. be careful that water does not enter the brake fluid reservoir. make sure the brake pipe “a” touches the projection “b” on the brake caliper. Mixing brake fluids may result in a harmful chemical reaction. Check: G Brake master cylinder “1” Damage/scratches/wear → Replace. ECA14170 and plastic parts. G Brake fluid delivery passages “2” (brake master cylinder body) 4-31 . place a container under the master cylinder and the end of the brake hose. Remove: G Union bolt G Copper washers G Brake hose NOTE: To collect any remaining brake fluid.REAR BRAKE BLE ROUTING” on page 2-30. Other brake fluids may cause the rubber seals to deteriorate. always clean up any spilt brake fluid immediately. 6. ECA13540 G Use CAUTION: Brake fluid may damage painted surfaces T. 12 ft•lb) 7. REMOVING THE REAR BRAKE MASTER CYLINDER NOTE: Before removing the rear brake master cylinder. 5. Therefore. Fill: G Brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended fluid DOT 4 EWA13090 only the designated brake fluid.7 m•kg. leading to poor brake performance. EAS22710 CHECKING THE REAR BRAKE MASTER CYLINDER 1. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. drain the brake fluid from the entire brake system. a 1 a 3. causing leakage and poor brake performance. CAUTION: When installing the brake hose onto the brake caliper “1”. 1.

G Brake master cylinder reservoir diaphragm holder G Brake master cylinder reservoir diaphragm Cracks/damage → Replace.REAR BRAKE Obstruction → Blow out with compressed air. causing leakage and poor 4-32 . Fill: G Brake fluid reservoir Recommended fluid DOT 4 EWA13090 WARNING G Use only the designated brake fluid. Check: G Master cylinder reservoir cap Cracks/damage → Replace. 22 ft•lb) EWA13530 Proper brake hose routing is essential to insure safe vehicle operation. a 2. Install: G Cylinder cup New G Master cylinder piston 2. G Never use solvents on internal brake components. Refer to “CABLE ROUTING” on page 2-30. Other brake fluids may cause the rubber seals to deteriorate. make sure the brake pipe touch the projection “a” as shown. 3. Check: G Brake master cylinder kit Damage/wear → Replace. Install: G Spring “1” New G Master cylinder piston “2” New G Adjusting rod “3” New G Circlip “4” New G Dust boot “5” New G Before When installing the brake hose onto the brake master cylinder. Install: G Copper washers New G Brake hoses G Union bolt Brake hose union bolt 30 Nm (30. EAS22730 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Recommended fluid DOT 4 1. Check: G Brake hoses Cracks/damage/wear → Replace. ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13520 CAUTION: WARNING installation. 1 2 EAS22750 2. all internal brake components should be cleaned and lubricated with clean or new brake fluid. WARNING R. m•kg. 4. ECA32D1002 T.

REAR BRAKE brake performance. 4. G Refill ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts. always clean up any spilt brake fluid immediately. G When refilling. a 5. Bleed: G Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. leading to poor brake performance. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 1-25. 3. be careful that water does not enter the brake fluid reservoir. Check: G Brake pedal operation Soft or spongy feeling → Bleed the brake system. with the same type of brake fluid that is already in the system. Check: G Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Mixing brake fluids may result in a harmful chemical reaction. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 1-23. Therefore. 4-33 . Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

R.0 m • kg. R. 20 ft • Ib) 7 Nm (0. 22 ft • Ib) 40 Nm (4. 5. 16 17 4 10 18 2 12 1 9 11 R.8 m • kg. 7 Nm (0.HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 7 T. R. 29 ft • Ib) T. T. 5.1 ft • Ib) 28 Nm (2.7 m • kg. T. 8 6 5 3 R. Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Job/Parts to remove Rear view mirror (left/right) Front brake light switch Front brake master cylinder holder Front brake master cylinder assembly Right handlebar switch Throttle cable housing Throttle cable Throttle grip Clutch cable Clutch switch Clutch lever holder Clutch lever Left handlebar switch Handlebar grip Special washer Handlebar upper holder Handlebar Handlebar lower holder Q’ty 1/1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 2 Remarks 4-34 . 1 13 15 14 30 Nm (3.7 m • kg.0 m • kg.1 ft • Ib) T.

29 ft • Ib) T. 1 13 15 14 30 Nm (3. R. T. 22 ft • Ib) 40 Nm (4. 5. 8 6 5 3 R. 20 ft • Ib) 7 Nm (0.1 ft • Ib) 28 Nm (2. R. 16 17 4 10 18 2 12 1 9 11 R.7 m • kg.7 m • kg. reverse the removal procedure.0 m • kg. Order Job/Parts to remove Q’ty Remarks For installation. 7 Nm (0.8 m • kg. 5. T.0 m • kg. 4-35 .HANDLEBAR Removing the handlebar 7 T.1 ft • Ib) T. R.

1 a b EAS22880 CHECKING THE HANDLEBAR 1. 3. 2. and gradually push the grip off the handlebar. adjust the handlebar position. 2. Remove: G Front brake switch G Clutch switch Securely support the vehicle so that there is no danger of it falling over. tighten the bolts on the front side of the handlebar holder. and remove them from front brake master cylinder assembly and clutch lever assembly. 3. Install: G Special washer G Handle grip 4-36 . and then on the rear side. EWA13690 WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken it. R. 20 ft•lb) NOTE: NOTE: the punch marks “a” on the handlebar with the upper surface of the lower handlebar holders. Stand the vehicle on a level surface. 2 2 G First.HANDLEBAR EAS22860 EAS22921 REMOVING THE HANDLEBARS 1. Install: G Handlebar “1” G Upper handlebar holders “2” Upper handlebar holder bolt 28 Nm (2. G Turn the handlebar all the way to the left and right. Press the projection. Check: G Handlebar Bends/cracks/damage → Replace. If there is any contact with the fuel tank. Stand the vehicle on a level surface. EWA13120 WARNING WARNING Securely support the vehicle so that there is no danger of it falling over.8 m•kg. G The upper handlebar holders should be installed with the punch marks “b” facing forward. Remove: G Handlebar grip “1” NOTE: CAUTION: Blow compressed air between the left handlebar and the handlebar grip. ECA14250 G Align T. EWA13120 INSTALLING THE HANDLEBAR 1.

1 ft•lb) Align the mating surfaces of the brake lever holder with the punch mark “a” on the handlebar. mount the throttle grip onto the handlebar. EWA32D1005 projection “a” of slot cable housing with hole “b” of the handlebar. Install: G Throttle grip “1” G Throttle cable housing “2” G Throttle cables “3” the front brake master cylinder on the front brake master cylinder assembly by facing the cylinder " “UP” mark upward.HANDLEBAR MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM NOTE: a. Install: G Clutch lever holder “1” G Clutch lever “2” NOTE: 1 b a 8. a b 5. G Install T. G Tighten the upper bolt first. 3 2 b a 1 G Align WARNING Do not touch and move the handlebar grip until its adhesive dries completely. Slightly coat the handlebar left end with a rubber adhesive. 1 c G Align 7. G Align the matching surface of front brake master cylinder holder with mark “a” of handlebar.7 m•kg. G Install the handlebar grip on the handlebar by pressing the grip from the left side. Install: G Right handlebar switch “1” NOTE: Align projection “a” of the right handlebar switch with hole “b” of the handlebar. Install: G Left handlebar switch “1” NOTE: tab “a” of special washer with slot “b” of left handlebar switch. 4-37 . R. and then tighten the lower bolt. Install: G Front master cylinder assembly “1” G Front brake master cylinder holder “2” Front brake master cylinder holder bolt 7 Nm (0. G Wipe off any excess rubber adhesive with a clean rag. 1 a NOTE: 2 6. G Slightly coat the end of slot cable and inside of throttle grip with lithium-soap-based grease. 5. Then. G Align the mating surfaces of the left handlebar switch with the punch mark “c” on the handlebar. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4.

0 mm (0.Adjust: G Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 1-8.39–0. Clutch lever free play 10.0–5.0–15. Adjust: G Clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” on page 1-14. Throttle cable free play 3.59 in) 10.0 mm (0.12–0.HANDLEBAR 1 a 2 9.20 in) 4-38 .

3 m • kg. Loosen.FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 30 Nm (3. 14 ft • Ib) 7 Nm (0.0 m • kg. R.7 m • kg. 6 7 T. For installation. 22 ft • Ib) 4 23 Nm (2. 17 ft • Ib) T. 17 ft • Ib) T. 23 Nm (2. 5. R. 5.1 ft • Ib) T. Loosen. R.7 m • kg. 2 1 3 7 Nm (0. 4-39 . T. reverse the removal procedure.0 m • kg. R. Loosen.3 m • kg. R. R.1 ft • Ib) T. 5 20 Nm (2. Order 1 2 3 4 5 6 7 Job/Parts to remove Front wheel Front fork protector Brake hose holder Front brake caliper Upper bracket pinch bolt Front fork cap bolt Lower bracket pinch bolt Front fork Q’ty 1 2 1 2 1 2 1 Remarks Refer to“FRONT WHEEL” on page 4-2.

12 11 LT 55 Nm (5. R. R.0 m • kg. 40 ft • Ib) 13 10 20 Job/Parts to remove Front fork cap bolt O-ring Rod Spring seat Fork spring Nut Spring guide Dust seal Stopper ring Base valve Copper washer O-ring Damper rod Outer tube Oil seal Oil sealWasher Slide metal Piston metal Inner tube Rubber cap Q’ty 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Remarks T. 5 16 15 2 4 14 R. 11 ft • Ib) T. 22 ft • Ib) T.5 m • kg.FRONT FORK Disassembling the front fork legs 30 Nm (3. Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 4-40 . 3 1 7 18 17 19 9 8 6 15 Nm (1.5 m • kg.

0 m • kg. Order 4-41 .5 m • kg.FRONT FORK Disassembling the front fork legs 30 Nm (3. 22 ft • Ib) T. reverse the disassembly procedure.5 m • kg. 3 1 7 18 17 19 9 8 6 15 Nm (1. 40 ft • Ib) 13 10 20 Job/Parts to remove Q’ty Remarks For assembly. 11 ft • Ib) T. R. R. 12 11 LT 55 Nm (5. T. 5 16 15 2 4 14 R.

loosen the damper rod assembly bolt. G Record the adjusting screw setting position before loosening the cap bolt. NOTE: the vehicle on a suitable stand so that the front wheel is elevated. Loosen: G Upper bracket pinch bolts “1” G Front fork cap bolt “2” G Lower bracket pinch bolts “3” EWA13640 G Place 2. Damper rod holder 90890-01454 4-42 . 3 2 Drain the fork oil by stroking the inner tube several times. 1. Drain: G Fork oil NOTE: WARNING Before loosening the upper and lower bracket pinch bolts. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Remove: G Cap bolt “1” (from outer tube) (by loosening the nut “2”) 5. Remove: G Dust seal “1” G Stopper ring “2” (with a flat-head screwdriver) ECA14180 CAUTION: 1 Do not scratch the inner tube.FRONT FORK EAS22970 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. support the front fork leg. 3. 2. Remove: G Nut G Spring guide G Push rod G Front fork spring G Spring guide 3. 1. Remove: G Front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Remove: G Base valve “1” G Copper washer G Damper rod NOTE: While holding the damper rod assembly “3” with the damper rod holder “2”. 4.

Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully. b. 1. Securely clamp the brake caliper bracket in a vise with soft jaws.FRONT FORK 6. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Check: G Push rod Bends/damage/wear → Replace. 3.72 in) Limit 441.0 mm (17. EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Hold the front fork leg horizontally. c.0 mm (17. Fork spring free length 450. 4-43 . Measure: G Spring free length “a” Out of specification → Replace. Check: G Base valve Damage/wear → Replace. Obstruction → Blow out all of the oil passages with compressed air. 2. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.36 in) 5. Check: G Inner tube G Outer tube Bends/damage/scratches → Replace. Check: G Damper rod “1” Damage/wear → Replace. Remove: G Inner tube “1” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. 6. 4. Obstruction → Blow out all of the oil passages with compressed air. Check: G Cap bolt Damage/wear → Replace.

G Uneven oil levels can result in poor handling and a loss of stability. tighten the base valve. make sure all of the components are clean.5 m•kg. Damper rod holder 90890-01454 Allow the damper rod assembly to slide slowly down the inner tube until it protrudes from the bottom of the inner tube. R.FRONT FORK EWA13660 WARNING sure the oil levels in both front fork legs are equal. 2. 2 4. Lubricate: G Inner tube’s outer surface Recommended oil Suspension oil 01 3. be sure to replace the following parts: G Piston metal G Slide metal G Oil seal G Dust seal G Before assembling the front fork leg. Tighten: G Base valve “1” Base valve 55 Nm (5. 1. NOTE: G When G Make 1 assembling the front fork leg. Install: G O-ring “1” New G Copper washer New G Base valve “2” 5. 40 ft•lb) LOCTITE® T. Install: G Damper rod “1” G Inner tube “2” ECA14210 NOTE: CAUTION: While holding the damper rod assembly “3” with the damper rod holder “2”. Install: G Dust seal “1” G Stopper ring “2” G Oil seal “3” New G Oil seal washer “4” G Slide metal “5” New (on to the inner tube “6”) 4-44 . Be careful not to damage the inner tube.

Install: G Piston metal “1” New (on the inner tube) 7. G Lubricate the outer surface of the inner tube with fork oil. hammer the seal until you see the stopper ring slot of outer tube. using fork seal driver “3”) Fork seal driver 90890-01442 Adjstable fork seal driver (36–46 mm) YM-01442 2 1 6. G To protect the oil seal. Install: G Oil seal “1” Using fork seal driver "2". lubricate its lips with lithium soap base grease. NOTE: installing the oil seal. and mount the oil seal. Install: G Outer tube “1” (on the inner tube “2”) 9. Fork seal driver 90890-01442 Adjstable fork seal driver (36–46 mm) YM-01442 4-45 . New 3 1 2 6 (a) 5 New G Before 4 8. cover it using polyethylene bag “b”. Install: G Slide metal “1” G Oil washer “2” (on the outer tube.FRONT FORK ECA32D1008 CAUTION: Face stamp "a" of the oil seal toward the front caliper mount during assembling.

Install: G Dust seal “1” (Slightly apply grease to the inner tube.Install: G Stopper ring “1” (in the slot of outer tube) CAUTION: G Be sure to use the recommended fork oil.Wait for 10 minutes to sediment and deaer- 4-46 . 250 mm) NOTE: Do not move more than 250 mm as it causes an air insertion.62 Imp.Check: G Inner tube for sliding Unsmooth sliding → Disassemble and check.When the front fork is filled with oil.FRONT FORK 13. 11. G When disassembling and assembling the front fork leg.) 14.Slowly move the inner tube up and down for lubrication again.73 US oz) (21. Other oils may have an adverse effect on front fork performance. NOTE: Move dumper rod slowly not to leak the fork oil. 12.Lubricate: G Front fork Recommended oil Suspension oil 01 Quantity 613. (1 stroke = Approx. 15. 16.0 cm3 (20. do not allow any foreign material to enter the front fork.oz) ECA14230 10. slowly move dumper rod “1” up and down (at least 10 times) for lubrication of fork.

FRONT FORK
ate the oil, then measure the fork oil level.
ECA32D1010

CAUTION:

Add the suspension oil to the top level of inner tube and deaerate the oil. If the oil is below this level, each part is not lubricated and you cannot get the desired spring performance. 17.Measure: G Front fork oil level “a” (at highest pressure) Out of specification → Adjust. Oil level 105 mm (4.13 in)

c. Tighten cap bolt “5” until it reaches nut “6” using your fingers. Nut 15 Nm (1.5 m•kg, 11 ft•lb)

T.

R.

18.Install: G Fork spring “1” G Push rod“ 2” G Spring guide “3” G Nut “4” G Cap bolt
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

d. Install the cap bolt on the outer tube, and tighten it temporarily.

a. Install the nut “3” with a finger until it is stopped. 2 4 3
LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL

1

EAS23050

b. Set adjusting screw “5” to the position before disassembling. Refer to “ADJUSTING THE FRONT FORK LEGS” on page 1-28.

INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: G Front fork leg Temporarily tighten the upper and lower bracket pinch bolts.
NOTE:

Install the front fork so that difference “a” between the cap bolt top face and upper bracket

4-47

FRONT FORK
top face becomes 3 mm, and tighten it temporarily.

a

2. Tighten: G Lower bracket pinch bolt “1” Lower bracket pinch bolt 20 Nm (2.0 m•kg, 14 ft•lb)

3. Tighten: G Cap bolt “2” Cap bolt 30 Nm (30. m•kg, 22 ft•lb)

4. Tighten: G Upper bracket pinch bolt “3” Upper bracket pinch bolt 23 Nm (2.3 m•kg, 17 ft•lb)

EWA32D1003

Check to see that the brake hose is installed correctly. Refer to “CABLE ROUTING” on page 2-30. 3 2

5. Adjust: G Rebound damping G Compression damping Refer to “ADJUSTING THE FRONT FORK LEGS” on page 1-28.

T.

WARNING

R.
T.

R.
T.

R.

1

4-48

STEERING HEAD
EAS23090

STEERING HEAD
Removing the headlight unit, meter assembly and front fender
23 Nm (2.3 m • kg, 17 ft • Ib)

6 4

7 Nm (0.7 m • kg, 5.1 ft • Ib) 4 Nm (0.4 m • kg, 2.9 ft • Ib)

T.

R.

7

T.

Order

R.

5

4

T.

R.

1 2

3

5 7

8

9

(4)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.

Job/Parts to remove Fuel tank Handlebar Front fork Brake hose guide Headlight assembly Headlight coupler Meter assembly coupler Front turn signal light connector (left/right) Meter assembly Turn signal light (left/right) Front fender Brake hose guide

R.

Q’ty

Remarks Refer to“FUEL TANK” on page 7-1. Refer to“HANDLEBAR” on page 4-34. Refer to“FRONT FORK” on page 4-39.

1 2 3 4 5 6 7 8 9

1 1 1 3 2/2 1 1/1 1 1

Disconnect. Disconnect. Disconnect.

For installation, reverse the removal procedure.

4-49

STEERING HEAD
3 4
120 Nm (12.0 m • kg, 87 ft • Ib)
T.

R.

13 12

5 6 7 8 10 11 13

38 Nm (3.8 m • kg, 27 ft • Ib) Loosen fully 2nd 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1st

T.

R

1

9 2

2

20 Nm (2.0 m • kg, 14 ft • Ib)

T.

R.

Order 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Parts to remove Headlight unit/Meter assemblies/Front fender Bracket Main switch coupler Steering stem nut Upper bracket Special washer Upper ring nut Rubber washer Lower ring nut Lower bracket Bearing cover Upper bearing Lower bearing Bearing races

Q’ty 1 2 1 1 1 1 1 1 1 1 1 1 2

Remarks Refer to“STEERING HEAD” on page 4-49. Disconnect.

For installation, reverse the removal procedure.

4-50

STEERING HEAD
EAS23110

REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface.
EWA13120

bracket with a floor chisel “2” and hammer. c. Install a new bearing races.
ECA14270

WARNING

CAUTION:

Securely support the vehicle so that there is no danger of it falling over. 2. Remove: G Upper ring nut G Lower ring nut “1”
NOTE:

If the bearing race is not installed properly, the steering head pipe could be damaged.
NOTE:

Always replace the bearings and bearing races as a set.

Hold the lower ring nut with the exhaust and steering nut wrench, and then remove the upper ring nut with the ring nut wrench. Ring nut wrench 90890-01268 Spanner wrench YU-01268
EWA13730

WARNING

Securely support the lower bracket so that there is no danger of it falling.

1

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL

EAS23120

CHECKING THE STEERING HEAD 1. Wash: G Bearings G Bearing races Recommended cleaning solvent Kerosene 2. Check: G Bearings G Bearing races Damage/pitting → Replace. 3. Replace: G Bearings G Bearing races
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

4. Check: G Upper bracket G Lower bracket (along with the steering stem) Bends/cracks/damage → Replace.
EAS23140

INSTALLING THE STEERING HEAD 1. Lubricate: G Upper bearing G Lower bearing G Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: G Lower bracket G Lower ring nut “1” G Rubber washer “2” G Upper ring nut “3” G Special washer “4”

a. Remove the bearing races from the steering head pipe with a long rod “1” and hammer. b. Remove the bearing race from the lower

4-51

STEERING HEAD
Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 1-27.

4

3 2 1

3. Install: G Upper bracket G Steering stem nut
NOTE:

Temporarily tighten the steering stem nut. 4. Install: G Front fork legs Refer to “FRONT FORK” on page 4-39.
NOTE:

Temporarily tighten the upper and lower bracket pinch bolts. 5. Tighten: G Steering stem nut Steering stem nut 120 Nm (12.0 m•kg, 87 ft•lb)

T.

R.

4-52

REAR SHOCK ABSORBER ASSEMBLY
EAS23160

REAR SHOCK ABSORBER ASSEMBLY
Removing the rear shock absorber assembly

4

40 Nm (4.0 m • kg, 29 ft • Ib)

T.

R.

80 Nm (8.0 m • kg, 58 ft • Ib)

T.

R.

LS

70 Nm (7.0 m • kg, 51 ft • Ib)

T.

R.
T.

80 Nm (8.0 m • kg, 58 ft • Ib)
LS

R.

LS

1 10 8
LS LS

9 10 2 9

6 7 13 12 6 7
LS

13 5
LS LS

3 6 11

53 Nm (5.3 m • kg, 38 ft • Ib)

T.

R.

Order

Job/Parts to remove Left slide cover/Right slide cover Drive chain tensioner top Rear shock absorber assembly Connection rod Relay arm Collar (short) Collar (long) Oil seal Bearing Collar Oil seal Bearing Collar Bearing Oil seal

Q’ty

Remarks Refer to“GENERAL CHASSIS” on page 4-1. Refer to“CHAIN DRIVE” on page 4-59.

1 2 3 4 5 6 7 8 9 10 11 12 13

1 1 1 1 1 4 2 1 2 2 1 1 2 For installation, reverse the removal procedure.

4-53

EWA13760 3. Rear shock absorber damage will result in poor damping performance. Check: G Connecting rod G Relay arm 4-54 . drill a 2–3-mm hole through the rear shock absorber at a point 30–35 mm from its end as shown. 2 1 DISPOSING OF A REAR SHOCK ABSORBER 1. EAS23240 WARNING Wear eye protection to prevent eye damage from released gas or metal chips. Before handling the rear shock absorber. read and make sure you understand the following information. EAS23260 WARNING Securely support the vehicle so that there is no danger of it falling over. Remove: G Rear shock absorber assembly upper bolt G Rear shock absorber assembly NOTE: Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm and relay arm. To release the gas pressure. G Do not deform or damage the rear shock absorber in any way. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. 2. EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Remove: G Connecting arm bolt “1” G Rear shock absorber assembly lower bolt “2” NOTE: This rear shock absorber contains highly compressed nitrogen gas. CHECKING THE CONNECTING ARM AND RELAY ARM 1. G Rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. G Bushings Damage/wear → Replace. G Spring Damage/wear → Replace the rear shock absorber assembly. Check: G Rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly.REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER EWA13740 NOTE: WARNING Place the vehicle on a suitable stand so that the rear wheel is elevated. hold the swingarm so that it does not drop down. EAS23190 While removing the rear shock absorber assembly lower bolt. EWA13120 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. G Bolts Bends/damage/wear → Replace. Gas pressure must be released before disposing of a rear shock absorber. G Do not tamper or attempt to open the rear shock absorber. Stand the vehicle on a level surface. G Do not subject the rear shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure.

24 in) Installed depth (connecting rod oil seal. 58 ft•lb) G Nut (Relay arm and swingarm) Nut (Relay arm and Swingarm) 70 Nm (7. Lubricate: G Oil seal G Bearings G Collar Recommended lubricant Lithium-soap-based grease 2.22 in) Installed depth (rear cushion lower bearing) “b” 4. lift up the swingarm.0 m•kg.16 in) Installed depth (relay arm bearing) “c” 6 mm (0.3 m•kg.0 mm (0. Install: G Rear shock absorber assembly NOTE: installing the rear shock absorber assembly. Check: G Bearings G Oil seals Damage/pitting → Replace. 2. relay arm. 29 ft•lb) G When G Nut (Frame and connecting rod) Nut (Frame and connecting rod) 80 Nm (8. Install: G Bearing “1” (To connecting rod “2”) G Bearing “3” (To relay arm “4”) G Bearing “5” (To rear cushion lower position “6”) G Oil seal “7” (To the connecting rod. R. 2. 58 ft•lb) G Nut (Relay arm and connecting rod) Nut (Relay arm and connecting rod) 80 Nm (8. T.0 m•kg.20–0.0 m•kg. 1 7 a d c d 4-55 .02–0. 38 ft•lb) T. G Install all bolts from the left side. T.5 mm (0.5-1.0 mm (0. a d 2 c d 7 T.5 mm (0–0.02 in) Installed depth (rear cushion lower oil seal) “e” 0.0 m•kg. Check: G Collar Damage/scratches → Replace. and rear cushion lower position) Installed depth (connecting rod bearing) “a” 5. relaly arm oil seal) “d” 0-0. 3. R. T. R. 51 ft•lb) G Nut (Rear shock absorber assembly lower and Relay arm) Nut (Rear shock absorber assembly lower and Relay arm) 53 Nm (5.04 in) 7 c d EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. EAS23270 7 b e e b 6 5 7 4 c d 3 INSTALLING THE RELAY ARM 1. R.REAR SHOCK ABSORBER ASSEMBLY Damage/wear → Replace. Tighten: G Rear shock absorber assembly upper nut Rear shock absorber assembly upper nut 40 Nm (4. R.0–5.

5. Job/Parts to remove Rear wheel Bolt (Swingarm and relay arm) Brake hose holder Chain case Chain cover Chain support Pivot shaft nut Pivot shaft Swingarm Dust cover Front drive chain guide Collar Oil seal Bearing T. 10 8 4 Remarks Refer to“REAR WHEEL” on page 4-7. Q’ty 1 3 1 1 1 1 1 1 2 1 2 2 4 For installation. R.5 m • kg.4 ft • Ib) 70 Nm (7.SWINGARM EAS23330 SWINGARM Removing the swingarm 6 85 Nm (8.0 m • kg. 11 11 13 9 12 1 3 5 7 Nm (0. R.7 m • kg.7 m • kg. 2 13 12 13 13 7 T. 5. R. 62 ft • Ib) 2 Nm (0.1 ft • Ib) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 R. 2 9 T. 51 ft • Ib) T. 4-56 .2 m • kg. T. 1. R. reverse the removal procedure.1 ft • Ib) 7 Nm (0.

EWA13770 Securely support the vehicle so that there is no danger of it falling over. Check: G Dust covers G Collar G Washers G Oil seals Damage/wear → Replace. Install: G Bearing “1” G Oil seal “2” G Collar (Swingarm) 4-57 . d. INSTALLING THE SWINGARM 1.5 m•kg. bearings. Place the vehicle on a suitable stand so that the rear wheel is elevated. If the swingarm side play is out of specification. Check: G Swingarm Bends/cracks/damage → Replace. washers. Lubricate: G Bearings G Collar G Dust covers G Pivot shaft Recommended lubricant Lithium-soap-based grease 2. Pivot shaft nut 85 Nm (8. Bends → Replace. Swingarm side play (at the end of the swingarm) 0 mm (0 in) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS23360 CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. If swingarm vertical movement is not smooth or if there is binding. Measure the tightening torque of the pivot shaft nut. Check the swingarm vertical movement “b” by moving the swingarm up and down. and dust covers. Wash: G Pivot shaft G Dust covers G Collar G Washers G Bearings Recommended cleaning solvent Kerosene 4. Measure: G Swingarm side play G Swingarm vertical movement MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. EAS23380 b. G Bearings Damage/pitting → Replace. washers. 62 ft•lb) 3. NOTE: WARNING Do not attempt to straighten a bent pivot shaft. 2. c. T. and dust covers. Check: G Pivot shaft Roll the pivot shaft on a flat surface. R. check the spacers. check the spacers. bearings. EWA13120 WARNING 2. Measure the swingarm side play “a” by moving the swingarm from side to side.SWINGARM EAS23350 REMOVING THE SWINGARM 1.

0–50.0 mm (1.0 mm (0. Adjust: G Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 1-26. R.5–9. Drive chain slack WR250R 38. Install: G Rear wheel Refer to “REAR WHEEL” on page 4-7. 6.5 m•kg.57–1.33–0. Install: G Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-53. 62 ft•lb) 5. 4-58 .0–48.0 mm (1.35 in) Installed depth “c” 0–0.89 in) WR250X 40.50–1. 4.5 mm (0–0.97 in) T.02 in) c b c b a a a 1 b c 2 c 1 b a 3. Install: G Swing arm assembly Pivot shaft nut 85 Nm (8.SWINGARM Installed depth “a” 15 mm (0.59 in) Installed depth “b” 8.

2 ft • Ib) T. 23 Nm (2.3 m • kg. 5 6 T. R. For installation. 4-59 . 17 ft • Ib) T.3 m • kg.CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain 23 Nm (2.0 m • kg. T. 1 2 4 3 95 Nm (9. R.5 m • kg. reverse the removal procedure. Order 1 2 3 4 5 6 Job/Parts to remove Swingarm Drive sprocket cover Drive sprocket nut Drive sprocket Drive chain Drive chain tensioner top Drive chain tensioner bottom Q’ty 1 1 1 1 1 1 Remarks Refer to“SWINGARM” on page 4-56. 7. R. 69 ft • Ib) 10 Nm (1. 17 ft • Ib) R.

15-link length limit 239. Remove: G Drive sprocket nut “1” NOTE: G Return G Operate the bent tab of the locknut. at a different location each time. or replace. Clean: G Drive chain MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. b. Measure: G 15-link section “a” of the drive chain Out of specification → Replace the drive chain. G When LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 2. G Rear shock absorber Refer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-53. Check: G Drive chain Stiffness → Clean. Drive chain 15-link section length “c” = (length “a” between pin inner sides + length “b” between pin outer sides)/2 1 NOTE: 3. G Swingarm Refer to “SWINGARM” on page 4-56.CHAIN DRIVE EAS23420 REMOVING THE DRIVE CHAIN 1. Put the drive chain in kerosene and remove any remaining dirt. the rear brake. lubricate.3 mm (9. G After loosening the drive sprocket. G Perform this procedure 2–3 times. make sure that the drive chain is taut. and loosen the drive sprocket. remove the rear wheel and swingarm. Remove: G Rear wheel Refer to “REAR WHEEL” on page 4-7. Wipe the drive chain with a clean cloth. Measure the length “a” between the inner sides of the pins and the length “b” between the outer sides of the pins on a 15-link section a. 4-60 . Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. CHECKING THE DRIVE CHAIN 1. 4. b. 2. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. Remove: G Drive chain EAS23441 measuring a 15-link section of the drive chain. Calculate the length “c” of the 15-link section of the drive chain using the following formula. EWA13120 of the drive chain as shown in the illustration.42 in) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM 3.

use only kerosene to clean the drive chain. Therefore. G Do not soak the drive chain in kerosene for more than ten minutes. T. G Drive chain rollers “2” Damage/wear → Replace the drive chain.g. Remove the drive chain from the kerosene and completely dry it. 69 ft•lb) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. Install: G Swingarm Refer to “SWINGARM” on page 4-56. Tighten: G Drive sprocket nut “1” Drive sprocket nut 95 Nm (9. 4. EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 4-9. Never use high-pressure water or air. High-pressure methods could force dirt or water into the drive chain’s internals. G Rear wheel Refer to “REAR WHEEL” on page 4-7. and solvents will deteriorate the O-rings. R.CHAIN DRIVE c. or a coarse brush to clean the drive chain.. G Drive chain side plates “3” Damage/wear → Replace the drive chain. G This 5. Check: G O-rings “1” Damage → Replace the drive chain. ECA14290 CAUTION: motorcycle has a drive chain with small rubber O-rings “1” between the drive chain side plates. certain solvents (e. EAS23490 INSTALLING THE DRIVE CHAIN 1. 4-61 . Lubricate: G Drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains EAS23460 CHECKING THE DRIVE SPROCKET 1. steam. otherwise the O-rings can be damaged. gasoline. Lubricate: G Drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2. Check: G Drive sprocket Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 4-9. A coarse brush can also damage the O-rings. benzine).5 m•kg. Install: G Drive chain G Drive sprocket G Drive sprocket nut (temporarily) 3.

0 mm (1.0 mm (1. and one that is too loose can skip and damage the swingarm or cause an accident. Drive chain slack WR250R 38.97 in) ECA13550 CAUTION: A drive chain that is too tight will overload the engine and other vital parts. 4-62 . tighten the drive sprocket nut. Adjust: G Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 1-26.0–50.0–48. G While 1 5.50–1. keep the drive chain slack within the specified limits.CHAIN DRIVE NOTE: applying the rear brake.57–1. G Stake the nut “1”. Therefore.89 in) WR250X 40.

.......................................................................................5-39 CHECKING THE CLUTCH PUSH RODS ..............................5-22 CHECKING THE VALVE LIFTERS.....................................................5-30 CHECKING THE STARTER MOTOR ..........................................5-26 CHECKING THE CYLINDER AND PISTON ....................................................................................................................................................................5-38 CHECKING THE CLUTCH PLATES.........................5-39 CHECKING THE PRIMARY DRIVE GEAR.5-17 REMOVING THE VALVES..............5-8 CHECKING THE CAMSHAFT ..........5-38 CHECKING THE CLUTCH SPRINGS ......5-40 1 2 3 4 5 6 7 8 9 ....5-10 CHECKING THE DECOMPRESSION SYSTEM ...........................5-20 CHECKING THE VALVE SPRINGS .................................................................................................................................................................5-15 VALVES AND VALVE SPRINGS .............................................................................................................5-23 INSTALLING THE VALVES ...........................................5-26 CHECKING THE PISTON RINGS ..........................................................................5-15 INSTALLING THE CYLINDER HEAD ..............................5-5 CAMSHAFT............................5-39 CHECKING THE CLUTCH BOSS........................5-38 CHECKING THE FRICTION PLATES .............5-23 CYLINDER AND PISTON ............................5-40 INSTALLING THE CLUTCH......................5-11 INSTALLING THE CAMSHAFTS .......................................5-27 INSTALLING THE PISTON AND CYLINDER ...............................................................................................................................................................................................................................................5-19 CHECKING THE VALVE SEATS....................................................................................................................5-25 REMOVING THE PISTON ....................5-1 INSTALLING THE ENGINE .............................................................5-11 CYLINDER HEAD ....................5-10 CHECKING THE TIMING CHAIN TENSIONERS ...................................................................................5-39 CHECKING THE CLUTCH HOUSING.........................................................5-18 CHECKING THE VALVES AND VALVE GUIDES ....................................................5-40 CHECKING THE PRIMARY DRIVEN GEAR ...............5-6 REMOVING THE CAMSHAFT........................................................................................................5-28 STARTER MOTOR ............................................................................................5-5 INSTALLING THE SHIFT PEDAL .........5-15 CHECKING THE CYLINDER HEAD ..........................5-32 ASSEMBLING THE STARTER MOTOR...............................5-39 CHECKING THE PRESSURE PLATE .............................5-27 CHECKING THE PISTON PIN............................................................................................................................................................................ENGINE ENGINE REMOVAL .................5-34 REMOVING THE CLUTCH ...................................5-14 REMOVING THE CYLINDER HEAD .............................................................................................................................................................................................................5-33 CLUTCH ............................................................5-8 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET .............................................

.......................................................5-67 CHECKING THE TRANSMISSION......................................................5-59 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ...................................................................5-43 CHECKING THE SHIFT SHAFT ........................................................5-54 CRANKCASE.........5-59 CHECKING THE TIMING CHAIN........................................................................................................................................................................................................................................5-59 CHECKING THE CRANKCASE................5-47 CHECKING THE OIL PUMP ...................................5-56 DISASSEMBLING THE CRANKCASE ............5-67 CHECKING THE SHIFT DRUM ASSEMBLY...........................5-67 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY .....5-61 REMOVING THE CRANKSHAFT ASSEMBLY..........5-47 ASSEMBLING THE OIL PUMP...........5-45 REMOVING THE OIL PUMP ............................................................................................................................................5-59 ASSEMBLING THE CRANKCASE ................................................................................5-64 CHECKING THE SHIFT FORKS .....5-69 ....5-44 INSTALLING THE SHIFT SHAFT ..................................5-48 GENERATOR AND STARTER CLUTCH ........5-47 INSTALLING THE OIL PUMP AND BALANCER GEAR....5-62 CHECKING THE CRANKSHAFT ASSEMBLY ..................................................................................................................................................................5-53 CHECKING THE STARTER CLUTCH...............5-54 INSTALLING THE GENERATOR ........................................ DELIVERY PIPE ......... NOZZLE...5-62 INSTALLING THE CRANKSHAFT ASSEMBLY .............5-62 TRANSMISSION ................5-44 OIL PUMP AND BALANCER GEAR ........................................................................................5-44 CHECKING THE STOPPER LEVER ..............5-68 INSTALLING THE TRANSMISSION..............................................................5-50 REMOVING THE GENERATOR............................................................................................................................................................................................................................SHIFT SHAFT ....... OIL STRAINER............................................5-53 INSTALLING THE STARTER CLUTCH.................................................. TIMING CHAIN GUIDE.............

5-1 . T.2 ft • Ib) T. 7.7 m • kg.2 ft • Ib) 42 Nm (4. 5. 30 ft • Ib) T. 2 6 20 Nm (2.ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe 7 Nm (0. 7 8 10 Nm (1.2 m • kg.0 m • kg. R. reverse the removal procedure.0 m • kg.1 ft • Ib) Order 1 2 3 4 5 6 7 8 T. 7. Job/Parts to remove Q’ty Remarks Refer to“GENERAL CHASSIS” on page 4-1.0 m • kg. 4 R. Seat side cover (left/right) Air scoop (left/right) Muffler protector EXUP pulley cover Side cover right stay EXUP cable Muffler Exhaust pipe Exhaust pipe gasket Muffler gasket R. 20 Nm (2. R. Refer to“GENERAL CHASSIS” on page 4-1. 3 5 1 T. 1 1 1 2 1 1 1 1 For installation. 14 ft • Ib) R. R.0 m • kg. 10 Nm (1. 14 ft • Ib) T.

5-2 . 10 Nm (1. Refer to“STARTER MOTOR” on page 5-30. Order Coolant Job/Parts to remove Q’ty Remarks Drain. 13 ft • Ib) T. 7. Disconnect.2 ft • Ib) T. Disconnect. Refer to“CHANGING THE COOLANT” on page 3-18.0 m • kg. Disconnect.8 m • kg. R. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Radiator Starter motor Shift pedal Drive sprocket cover Gasket Drive sprocket nut Drive sprocket Speed sensor coupler Coolant temperature sensor coupler Generator coupler Crankshaft position sensor coupler Horn lead coupler Fuse box Side cover stay Ground lead Neutral switch lead Ignition coil lead coupler 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 Disconnect. Disconnect. R. Disconnect.ENGINE REMOVAL Removing the shift pedal.5 m • kg. Disconnect. 7. 11 14 12 9 1 10 8 5 3 2 4 95 Nm (9. R.2 ft • Ib) 18 Nm (1. Refer to“RADIATOR” on page 6-1. T. R.0 m • kg. 69 ft • Ib) T. leads and hoses 13 7 15 6 10 Nm (1.

R. 5-3 . Order Job/Parts to remove Q’ty Remarks For installation. 69 ft • Ib) T. T.0 m • kg. R. leads and hoses 13 7 15 6 10 Nm (1. 10 Nm (1.0 m • kg.8 m • kg. 7.2 ft • Ib) T.ENGINE REMOVAL Removing the shift pedal. reverse the removal procedure.5 m • kg.2 ft • Ib) 18 Nm (1. 7. R. 13 ft • Ib) T. 11 14 12 9 1 10 8 5 3 2 4 95 Nm (9. R.

Order R. 7 1 5 2 56 Nm (5.6 m • kg. reverse the removal procedure. 62 ft • Ib) T. 67 Nm (6.3 m • kg. Drain. 6 3 8 Job/Parts to remove Q’ty Remarks NOTE: Use a suitable stand to supported the engine side. Refer to“CHANGING THE ENGINE OIL” on page 3-11. Engine oil Engine mounting bolt (front upper) Engine mounting bolt (front) Engine mounting bolt (front lower) Down tube bolts (front upper) Down tube bolts (rear lower) Down tube Pivot shaft Engine assembly 1 1 1 2 2 1 1 1 For installation.7 m • kg. R. 5-4 . 113 Nm (11. 82 ft • Ib) 1 2 3 4 5 6 7 8 T.5 m • kg. 48 ft • Ib) 4 R.ENGINE REMOVAL 85 Nm (8. T. T. 41 ft • Ib) R.

41 ft•lb) 4 T. 48 ft•lb) Engine mounting nut (front) 56 Nm (5. Install: G Engine assembly “1” G Pivot shaft “2” G Down tube “3” G Down tube bolt (rear lower side) “4” G Down tube bolt (front upper side) “5” G Engine mounting bolt (front lower side) “6” G Engine mounting bolt (front) “7” G Engine mounting bolt (front upper side) “8” NOTE: INSTALLING THE SHIFT PEDAL 1. T.20 in) lower than the footrest top face.3 m•kg. 5 mm (0. 13 ft•lb) NOTE: Install the shift pedal so that pedal top face “a” is 5 mm (0. (Temporarily tighten) a a. Tighten: G Pivot shaft nut G Downtube nut (rear lower side) G Engine mounting nut Pivot shaft nut 85 Nm (8.7 m•kg. R. R.ENGINE REMOVAL EAS23720 EAS32D1009 INSTALLING THE ENGINE 1.8 m•kg. Install: G Shift pedal Shift pedal bolt 18 Nm (1. 41 ft•lb) Engine mounting nut (front upper side) 67 Nm (6. 62 ft•lb) Downtube nut (rear lower side) 113 Nm (11. 5-5 . 82 ft•lb) Engine mounting nut (front lower side) 56 Nm (5. 82 ft•lb) Downtube nut (front upper side) 113 Nm (11.6 m•kg. Do not fully tighten the bolts.3 m•kg.6 m•kg.5 m•kg.20 in) 5 8 1 7 2 6 3 2.

reverse the removal procedure. R. 4 5 8 7 13 Nm (1.2 m • kg.4 ft • Ib) T.3 m • kg. Refer to “FUEL TANK” on page 7-1. 2 3 Order R. For installation. Engine oil 1 2 3 4 5 6 7 8 9 Throttle cable Throttle body Clutch cable Ignition coil coupler Cylinder head cover breather hose Ignition coil assembly Spark plug Cylinder head cover Cylinder head cover gasket 2 1 1 1 1 1 1 1 1 Disconnect. 5-6 . Refer to “CHANGING THE COOLANT” on page 3-18. Drain. Disconnect. 9 1 Job/Parts to remove Side cover (left/right) Fuel tank Coolant Q’ty Remarks Refer to “GENERAL CHASSIS” on page 4-1. 9. Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-11. 8.7 ft • Ib) T.CAMSHAFT EAS23730 CAMSHAFT Removing the cylinder head cover 6 12 Nm (1.

9 R.0 m • kg. R. 7. 17 ft • Ib) 10 Nm (1.2 ft • Ib) T. 7. 5-7 .2 ft • Ib) R. E 4 7 5 6 8 24 Nm (2. T. reverse the removal procedure.0 m • kg.4 m • kg.CAMSHAFT REMOVING THE CAMSHAFT E T. M M 3 1 2 Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Timing mark accessing screw Crankshaft end cover Timing chain tensioner assembly Camshaft cap Dowel pin Camshaft (IN) Camshaft (EX) Camshaft sprocket (IN) Camshaft sprocket (EX) Q’ty 1 1 1 1 2 1 1 1 1 Remarks For installation. 10 Nm (1.

CAMSHAFT
EAS23800

REMOVING THE CAMSHAFT 1. Remove: G Crankshaft end cover G Timing mark accessing screw 2. Align: G TDC on the generator rotor (mark on the crankcase cover)
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

5

3

1

7

8

2

4

6

a. Turn the crankshaft counterclockwise. b. When piston is at TDC on the compression stroke, align the mark “a” on the generator rotor with the mark “b” on the crankcase cover.
NOTE:

7. Remove: G Intake camshaft “1” G Exhaust camshaft “2”
NOTE:

TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. b a

To prevent the timing chain from falling into the crankcase, fasten it with a wire to it. 2

1

EAS23840

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL

3. Remove: G Cylinder head cover 4. Loosen: G Camshaft sprocket bolt 5. Remove: G Timing chain tensioner assembly G Gasket 6. Remove: G Camshaft cap bolts G Camshaft cap
ECA32D1006

CHECKING THE CAMSHAFT 1. Check: G Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: G Camshaft lobe dimensions “a” and “b” Out of specification → Replace the camshaft.

CAUTION:

To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in satages and in order from 1 to 8.

5-8

CAMSHAFT
Camshaft lobe dimension limit Intake A 34.550–34.650 mm (1.3602–1.3642 in) Limit 35.450 mm (1.3957 in) Intake B 25.953–26.053 mm (1.0218–1.0257 in) Limit 25.853 mm (1.0178 in) Exhaust A 34.850–34.950 mm (1.3720–1.3760 in) Limit 34.750 mm (1.3681 in) Exhaust B 25.986–26.086 mm (1.0231–1.0270 in) Limit 25.886 mm (1.0191 in)

4. Measure: G Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Limit 0.08 mm (0.0031 in)
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position a strip of Plastigauge® “1” onto the camshaft journal as shown. 1

c. Install the dowel pins and camshaft caps.
NOTE:

3. Measure: G Camshaft runout Out of specification → Replace. Camshaft runout limit 0.015 mm (0.00059 in) or less

the camshaft cap bolts in the order of the embossed numbers on the camshaft cap. G Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance. Camshaft cap bolts 10 Nm (1.0 m•kg, 7.2 ft•lb)

G Tighten

d. Remove the camshaft caps and then measure the width of the Plastigauge® “1”.

T.

R.

5-9

CAMSHAFT
1 b

a

1 2

a. 1/4 tooth b. Correct
LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL

5. Measure: G Camshaft journal diameter “a” Out of specification → Replace the camshaft. Within specification → Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 21.959–21.972 mm (0.864–0.865 in)

1. Timing chain roller 2. Camshaft sprocket
EAS23960

CHECKING THE TIMING CHAIN TENSIONERS The following procedure applies to both of the timing chain tensioners. 1. Check: G Timing chain tensioner Cracks/damage → Replace.
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

a. Using a finger, push and insert timing chain tensioner rod “1” into the timing chain tensioner housing.
NOTE:

Push the timing chain tensioner rod in direction “a”, and turn the timing chain tensioner body “2” in direction “b” until it stops. 2
EAS23870

CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET 1. Check: G Timing chain “1” Damage/stiffness → Replace the timing chain and camshaft and camshaft sprocket as a set. 2. Check: G Camshaft sprocket More than 1/4 tooth wear “a” → Replace the camshaft sprocket and the timing chain as a set.

b a 1

b. Keep pressing the timing chain tensioner rod, mount clip “3” into groove “4”, and lock the timing chain tensioner rod. c. Push the timing chain tensioner rod in direction “c”. d. Make sure that the timing chain tensioner rod can smoothly move out from the timing chain tensioner housing in direction “d”. If not smooth, replace the timing chain tensioner assembly.

5-10

CAMSHAFT
1 2

3 4

c

d

a 2. Install: G Intake camshaft sprocket G Exhaust camshaft sprocket

a

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL
EAS32D1001

MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

CHECKING THE DECOMPRESSION SYSTEM 1. Check: G Decompression system
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

a. Turn the crankshaft counterclockwise. b. When piston is at TDC on the compression stroke, align the mark “a” on the generator rotor with the mark “b” on the crankcase cover.

a. Check that the decompressor lever pin “1” projects from the camshaft. b. Check that the decompressor cam “2” moves smoothly. a

b

1 2

c. Install the timing chain onto both camshaft sprockets and then install the exhaust camshaft onto the cylinder head first.
NOTE:

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL
EAS24000

Locate mark “c” of exhaust system camshaft chain sprocket “1” and mark “d” of intake system camshaft chain sprocket “2” in the same position at the end of cylinder head as shown. This is the Top Dead Center (TDC).
ECA13740

INSTALLING THE CAMSHAFTS 1. Install: G Exhaust camshaft “1” G Intake camshaft “2” Camshaft sprocket bolt 24 Nm (2.4 m•kg, 17 ft•lb)

CAUTION:

Do not turn the crankshaft when installing the camshaft(s) to avoid damage or improper valve timing.

NOTE:

line “a” of the camshaft sprocket must locate in the position as shown. G Temporarily tighten the camshaft sprocket bolts.

G Stamp

T.

R.

5-11

CAMSHAFT
2 5 3 1 7

1

8

2

4

6

5. Install: G Timing chain tensioner
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

a. Using a finger, push and insert timing chain tensioner rod “1” into the timing chain tensioner housing.
NOTE:

c

d

Push the timing chain tensioner rod in direction “a”, and turn the timing chain tensioner body “2” in direction “b” until it stops. 2

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL

3. Install: G Dowel pin G Camshaft cap G Camshaft cap bolts
NOTE:

b a 1

the camshaft cap bolt threads with engine oil. G Finger tighten the camshaft cap bolts. 4. Tighten: G Camshaft cap bolts Camshaft cap bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) b. Keep pressing the timing chain tensioner rod, mount clip “3” into groove “4”, and lock the timing chain tensioner rod.

G Lubricate

NOTE:

Tighten the camshaft cap bolts in the order of the embossed numbers on the camshaft cap.
ECA13730

CAUTION:

The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result.

T.

R.

3 4

c

d

c. In the status of step “b”, install the rod assembly in the cylinder block.
NOTE:

Always use a new gasket. Timing chain tensioner bolt 10 Nm (1.0 m•kg, 7.2 ft•lb)

T.

R.

5-12

CAMSHAFT
d. Unlock the camshaft chain tensioner by turning the crankshaft counterclockwise, and tension the timing chain.
LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL

Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-4.

6. Turn: G Crankshaft (several turns counterclockwise) 7. Check: G The TDC mark of rotor, and the mark of crankshaft case cover
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM

a. Turn the crankshaft counterclockwise. b. When the piston is in the compression process, align TDC mark “a” of the rotor with mark “b” of crankshaft case cover.
NOTE:

You can check the TDC in compression process when the camshaft robes face outward.
G

Punch mark on the camshaft Check the matching of stamp line “c” of the camshaft punch mark timing chain sprocket and the cylinder head end. Out of alignment → Reinstall. Refer to the installation steps above. b a

c

c

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL

8. Measure: G Valve clearance Out of specification → Adjust.

5-13

CYLINDER HEAD
EAS24100

CYLINDER HEAD
Removing the cylinder head
40 Nm (4.0 m • kg, 29 ft • Ib)
T.

R.

E

E M

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.

R.

M E

1 2 3

3

Order

Job/Parts to remove Camshaft Hose (thermostat cover) Coolant temperature sensor coupler Thermostat Air induction pipe

Q’ty

Remarks Refer to“CAMSHAFT” on page 5-6. Refer to“THERMOSTAT” on page 6-4.

Refer to“AIR INDUCTION SYSTEM” on page 7-9. 1 1 2 For installation, reverse the removal procedure.

1 2 3

Cylinder head assembly Cylinder head gasket Dowel pin

5-14

d. c. Eliminate: G Combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: G Spark plug bore threads G Valve seats e. 2 2 c b EAS24160 1 f a 1 CHECKING THE CYLINDER HEAD 1. out of specification → Replace the cylinder head.002 in) INSTALLING THE CYLINDER HEAD 1. turn the cylinder head several times. 3. Check: G Cylinder head Damage/scratches → Replace. Measure: G Cylinder head warpage Out of specification → Resurface the cylinder head. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS24230 2. Install: G Cylinder head gasket “1” New G Dowel pins “2” 5-15 . G Cylinder head water jacket Mineral deposits/rust → Eliminate. Remove: G Cylinder head bolts “1” (M6×60) G Cylinder head bolts “2” (M10×154) G Cylinder head bolts “3” (M10×140) NOTE: MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Gradually loosen bolts “a” to “f” in this sequence in several times. Cylinder head warpage 0. Place a straightedge “1” and a thickness gauge “2” across the cylinder head. If the limit is exceeded. Place a 400–600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. Measure the warpage. 3 e d 3 a.05 mm (0. b.CYLINDER HEAD EAS24130 REMOVING THE CYLINDER HEAD 1. After resurfacing. resurface the cylinder head as follows. NOTE: To ensure an even surface.

Install: G Cylinder head NOTE: Pass the timing chain through the timing chain cavity. 1 b c 1 2 d e a f G Lubricate T.2 ft•lb) NOTE: the cylinder head bolts with engine oil. 29 ft•lb) Cylinder head bolt (M6) 10 Nm (1. 7. G Tighten the cylinder head bolts in the proper tightening sequence as shown and torque them in two stages. 3 5-16 .CYLINDER HEAD 4 M 4 M 4 New 1 2 2 2. R.0 m•kg. Tighten: G Cylinder head bolts (M10×140 )“1” G Cylinder head bolts (M10×155)“2” G Cylinder head bolts (M6×60 )“3” Cylinder head bolt (M10) 40 Nm (4.0 m•kg. 3.

For installation. reverse the removal procedure.VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs 1 1 2 M 2 3 4 4 5 8 9 5 8 9 3 M 6 7 M Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Cylinder head Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Exhaust valve Intake valve Valve stem seal Valve spring seat Q’ty 4 4 8 4 4 2 2 4 4 Remarks Refer to“CYLINDER HEAD” on page 5-14. 5-17 .

1. make sure the valves properly seal. a. and valve seat width. valves. 5-18 . Valve spring compressor 90890-04019 YM-04019 2 2 1 2. Check: G Valve sealing Leakage at the valve seat → Check the valve face. Remove: G Valve cotters “1” NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor “2”. valve springs. Check that the valves properly seal. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM 4. NOTE: Before removing the internal parts of the cylinder head (e. valve seat. Pour a clean solvent “a” into the intake and exhaust ports. Remove: G Valve spring retainer “1” G Valve spring “2” G Valve “3” G Valve stem seal “4” G Valve spring seat “5” NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. NOTE: There should be no leakage at the valve seat “1”. b. valve seats). Refer to “CHECKING THE VALVE SEATS” on page 5-20. Remove: G Valve lifter “1” G Valve pad “2” NOTE: 1 a Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place..g. 1 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3.VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components.

0004–0.0010–0.010–0.0039 in) Limit 0. 1.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.052 mm (0. 2 c. heat the cylinder head to 100°C (212°F) in an oven. Install the new valve guide with the valve guide installer “2” and valve guide remover “1”. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.0015 in) Limit 0.004 in) To ease valve guide removal and installation. bore the valve guide with the valve guide reamer “3” to obtain the proper valve-stem-to-valve-guide clearance. 5-19 . Replace: G Valve guide NOTE: EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides.100 mm (0.08 mm (0.10 mm (0.037 mm (0. 1 b. Measure: G Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide.0020 in) Limit 0.0032 in) Limit 0. Remove the valve guide with the valve guide remover “1”. Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” Valve stem diameter “b” Valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance (intake) 0.080 mm (0.025–0. After installing the valve guide.VALVES AND VALVE SPRINGS 1 2 4 5 3 2. and to maintain the correct fit.

0571 in) Limit 1.00 mm (0.010 mm (0.VALVES AND VALVE SPRINGS NOTE: After replacing the valve guide.0394 in) Valve margin thickness D (exhaust) 0.15–1. NOTE: installing a new valve. Measure: G Valve margin thickness “a” Out of specification → Replace the valve.0453 in) Limit 0.85–1. 5. Eliminate: G Carbon deposits (from the valve face and valve seat) 4. always replace the valve guide.10 mm (0. 1. Eliminate: G Carbon deposits (from the valve face and valve seat) 2. always replace the oil seal.0433 in) 5-20 .5) 90890-04118 YM-04118 6. Valve stem runout 0.90–1. Check: G Valve face Pitting/wear → Grind the valve face.0004 in) G When LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3. Valve margin thickness Valve margin thickness D (intake) 1.5) 90890-04116 YM-04116 Valve guide installer (ø4.0433 in) Valve seat width C (exhaust) 0.0276 in) EAS24300 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. reface the valve seat.90–1. Check: G Valve seat Pitting/wear → Replace the cylinder head.70 mm (0.45 mm (0. Valve seat width Valve seat width C (intake) 0. G Valve stem end Mushroom shape or diameter larger than the body of the valve stem → Replace the valve. Measure: G Valve seat width “a” Out of specification → Replace the cylinder head. Measure: G Valve stem runout Out of specification → Replace the valve. Valve guide remover (ø4. 3.10 mm (0.0354–0.0335–0.0354–0.15 mm (0.5) 90890-04117 YM-04117 Valve guide reamer (ø4. G If the valve is removed or replaced.0453–0.

NOTE: a For the best lapping results. be sure to clean off all of the lapping compound from the valve face and valve seat. Always replace lapped valves with new valves. Titaium valves that have been used to lap the valve seats must not be used.VALVES AND VALVE SPRINGS face should be lapped. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. lightly tap the valve seat while turning the valve back and forth between your hands. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face. replace the valves without lapping the valve seats and valve faces. NOTE: Where the valve seat and valve face contacted one another. Install the valve into the cylinder head. d. Measure the valve seat width “a”. 5-21 . After every lapping procedure. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear impression. NOTE: G When MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. then clean off all of the lapping compound. replacing the cylinder head. ECA32D1012 CAUTION: This model uses titanium intake valves. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. the blueing will have been removed. ECA13790 CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. Turn the valve until the valve face and valve seat are evenly polished. G When replacing the valves or valves guides. f. d. use new valves to lap the valve seats. the valve seat and valve e. Apply a coarse lapping compound “a” to the valve face. Lap: G Valve face G Valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide. c. Apply a fine lapping compound to the valve face and repeat the above steps. c. b. and then replace them with new valves. b. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face. Apply molybdenum disulfide oil onto the valve stem. g.

00 N (33. Measure: G Compressed valve spring force “a” Out of specification → Replace the valve spring. Measure: G Valve spring free length “a” Out of specification → Replace the valve spring.VALVES AND VALVE SPRINGS h.23 kgf) Installed length 31. Measure the valve seat width “c” again.03 mm (1. 2. Measure: G Valve spring tilt “a” Out of specification → Replace the valve spring. Installed length LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.42 in) Limit 34.00 N (33. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear impression.23 mm (1.99 lbf) (14.23 mm (1.99–17.99–17.05–37.00–169. Compressed valve spring force b. reface and lap the valve seat. a.6 mm Spring tilt (exhaust) 2.99 lbf) (14.6 mm 5-22 .22 in) 3.23 kgf) Installed compression spring force (exhaust) 147.5 °/1.00–169.5 °/1.03 mm (1.35 in) Free length (exhaust) 36. 1. j. Spring tilt limit Spring tilt (intake) 2.35 in) Installed compression spring force (intake) 147.05–37. If the valve seat width is out of specification. Valve spring free length Free length (intake) 36. i.42 in) Limit 34.00 mm (1.

1. G Install the valve springs with the larger pitch “a” facing up. 1. Valve spring compressor 90890-04019 YM-04019 2.VALVES AND VALVE SPRINGS EAS24320 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 3. Check: G Valve lifter Damage/scratches → Replace the valve lifters and cylinder head. Install: G Valve “1” G Spring seat “2” G Valve stem seal “3” G Valve spring “4” G Valve spring retainer “5” (onto the cylinder head) NOTE: G Make sure each valve is installed in its original place. Refer to the following embossed marks. Install: G Valve cotters “1” NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor attachment. Lubricate: G Valve stem “1” G Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 5-23 . Smaller pitch 4. Larger pitch b. EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. Deburr: G Valve stem end (with an oil stone) a.

ECA13800 CAUTION: Hitting the valve tip with excessive force could damage the valve. G Each valve lifter and valve pad must be rein- G The 5-24 . Lubricate: G Valve pad “1” G Valve lifter “2” Recommended lubricant Molybdenum disulfide oil 2 M 1 7. Install: G Valve pad G Valve lifter NOTE: valve lifter must move smoothly when rotated with a finger. 6.VALVES AND VALVE SPRINGS stalled in its original position. lightly tap the valve tip with a soft-face hammer. 2 1 5. To fasten the valve cotters “1” onto the valve stem.

5-25 .2 ft • Ib) T.CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston 10 Nm (1. R.0 m • kg. 7. 1 9 E 8 6 E 7 E 2 5 6 3 4 2 Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Cylinder head Cylinder Dowel pin Water pipe O-ring Cylinder gasket Piston pin clip Piston pin Piston Piston ring set Q’ty 1 2 1 1 1 2 1 1 1 Remarks Refer to“CYLINDER HEAD” on page 5-14. For installation. reverse the removal procedure.

031–3. cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. NOTE: removing the piston pin clip.002 in) Out of round limit 0. Remove: G Top ring G 2nd ring G Oil ring NOTE: Cylinder bore “D” 77. 2.CYLINDER AND PISTON EAS24380 REMOVING THE PISTON 1. Measure piston skirt diameter “P” with the micrometer. rebore or replace the cylinder.05 mm (0. If out of specification. NOTE: a. P a EAS24390 CHECKING THE CYLINDER AND PISTON 1. Measure: G Piston-to-cylinder clearance MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM CAUTION: Do not use a hammer to drive the piston pin out. find the average of the measurements. G Before removing the piston pin. b.100 mm (3. 3 2 1 2.035 in) Taper limit “T” 0.(maximum of D5 or D6) When removing a piston ring. 12 mm (0. and replace the piston and piston rings as a set. Measure cylinder bore “D” with the cylinder bore gauge. Then. Remove: G Piston pin clips “1” G Piston pin “2” G Piston “3” ECA13810 Vertical scratches → Rebore or replace the cylinder.010 mm (3.032 in) Limit 77. open the end gap with your fingers and lift the other side of the ring over the piston crown. deburr the piston pin clip’s groove and the piston’s pin bore area.47 in) from the bottom edge of the piston 5-26 .000–77.002 in) “D” = maximum of D1–D6 “T” = (maximum of D1 or D2) . G Before Measure cylinder bore “D” by taking side-to-side and front-to-back measurements of the cylinder. Check: G Piston wall (Sidewall) G Cylinder wall a.05 mm (0. c. and replace the piston and piston rings as a set.

15–0. 40 mm (1. CHECKING THE PISTON RINGS 1. If the oil ring rail’s gap is excessive.030–0.0022 in) Limit 0. NOTE: 3. Measure: G Piston pin outside diameter “a” Out of specification → Replace the piston pin.10 mm (0.0098 in) Limit 0.40 mm (0. piston and piston rings as a set.0045 in) Second ring side clearance (installed) 0.0039–0.0039 in) f. Install: G Piston ring (into the cylinder) NOTE: Level the piston ring into the cylinder with the piston crown.115 mm (0. Piston ring side clearance Top ring side clearance (installed) 0.0118–0.80 mm (0. 5-27 . If out of specification. replace the cylinder.57 in) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS24430 2. replace the cylinder. eliminate any carbon deposits from the piston ring grooves and piston rings.055 mm (0.50 mm (0.45 mm (0.031 in) Oil ring End gap (installed) 0.30–0.0059–0.0012–0. Check: G Piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubrication system.0004–0. If out of specification.CYLINDER AND PISTON d.065 mm (0.25 mm (0.020–0.10–0.010–0.0014 in) Limit 0. Piston-to-cylinder clearance = Cylinder bore “D” Piston skirt diameter “P” Piston-to-cylinder clearance 0.0008–0. piston and piston rings as a set.115 mm (0. NOTE: The oil ring expander spacer’s end gap cannot be measured. 2.035 mm (0.0177 in) Limit 0. Measure: G Piston ring side clearance Out of specification → Replace the piston and piston rings as a set.0045 in) CHECKING THE PISTON PIN 1. replace all three piston rings.020 in) 2nd ring End gap (installed) 0.0157 in) EAS24440 Before measuring the piston ring side clearance. Measure: G Piston ring end gap Out of specification → Replace the piston ring. e.0026 in) Limit 0. a. Piston ring end gap Top ring End gap (installed) 0. Calculate the piston-to-cylinder clearance with the following formula.

Calculate: G Piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin and piston as a set.043 mm (0. Piston pin bore inside diameter 17. G Before installing the piston pin clip. cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase. Install: G Top ring “1” G 2nd ring “2” G Lower oil ring rail “3” G Upper oil ring rail “4” G Oil ring expander “5” NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.00087 in) 3.6693 in) Limit 16.991–17.000 mm (0. Install: G Piston “1” G Piston pin “2” G Piston pin clips “3” New NOTE: engine oil the piston pin.668 in) INSTALLING THE PISTON AND CYLINDER 1.971 mm (0.022 mm (0.6689–0. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter “b” Piston pin outside diameter “a” Piston pin/piston pin hole clearance 0.670 in) 2.6694–0.002–0.6698 in) Limit 17. Install: G Cylinder gasket New G Water pipe “1” G Dowel pins “2” G O-ring “3” New b 4. sure the mark “a” on the piston points towards the exhaust side of the cylinder. 3.002–17.013 mm (0. G Make G Apply 5-28 . Measure: G Piston pin bore diameter “b” Out of specification → Replace the piston.CYLINDER AND PISTON EAS24450 Piston pin outside diameter 16.00008–0.

CYLINDER AND PISTON a 1 2 3 New 4. 2nd ring f. Install: G Cylinder Cylinder bolt 10 Nm (1. G Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity. R. Oil ring expander d. Top ring b.0 m•kg. 5-29 .2 ft•lb) NOTE: compressing the piston rings with one hand. G While T. Upper oil ring rail c. 20 mm 6. install the cylinder with the other hand. 7. Lubricate: G Piston G Piston rings G Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: G Piston ring end gaps a. Lower oil ring rail e.

6 ft • Ib) 1 10 Nm (1.0 m • kg. Refer to “ENGINE REMOVAL” on page 5-1.5 m • kg. Disconnect.2 ft • Ib) Order T. 1 2 EXUP cable/Exhaust pipe/Muffler Starter motor lead Starter motor 1 1 5-30 . R. 2 Job/Parts to remove Seat/Air scoop (left/ritht) Q’ty Remarks Refer to “GENERAL CHASSIS” on page 4-1.STARTER MOTOR EAS24780 STARTER MOTOR Removing the starter motor 5 Nm (0. T. reverse the disassembly procedure. 3. For assembly. R. 7.

STARTER MOTOR Disassembling the starter motor 5 6 4 3 2 1 Order 1 2 3 4 5 6 Job/Parts to remove Starter motor front cover Lock washer Armature assembly Starter motor yoke Starter motor rear cover Brush holder set Q’ty 1 1 1 1 1 1 Remarks For assembly. reverse the disassembly procedure. 5-31 .

If any resistance is out of specification. replace the starter motor. 2. Measure: G Armature assembly resistances (commutator and insulation) Out of specification → Replace the starter motor. 3.06 in) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Armature coil Commutator resistance “1” 0.STARTER MOTOR EAS24790 CHECKING THE STARTER MOTOR 1. Measure: G Commutator diameter “1” Out of specification → Replace the starter motor. Mica undercut (depth) 0.70 mm (0.77–34. Limit 3. 4.52 N (25.14 in) The mica of the commutator must be undercut to ensure proper operation of the commutator. Check: G Commutator Dirt → Clean with 600 grit sandpaper.005 Ω at 20°C (68°F) Insulation resistance “2” Above 1 MΩ at 20°C (68°F) b. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM 6.16–9.27 oz) (730–971 gf) a.004–0. Measure: G Brush length “a” Out of specification → Replace the brushes as a set. Limit 27. Measure the armature assembly resistances with the pocket tester. 5-32 . Brush spring force 7. Measure: G Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.03 in) NOTE: LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 5.0 mm (1.50 mm (0. Measure: G Brush spring force Out of specification → Replace the brush springs as a set.

Check: G Bearing G Oil seal Damage/wear → Replace the defective part (s). EAS24800 3 1 2 ASSEMBLING THE STARTER MOTOR 1. 5-33 . 2 1 2. Check: G Gear teeth Damage/wear → Replace the gear. 8. Install: G Brush holder “1” NOTE: b a Align the tab on the brush seat with the slot in the starter motor rear cover “2”. Install: G Thrust support “1” NOTE: Align the tab of thrust support with the slot of stator motor front cover “2”. 2 1 3.STARTER MOTOR 7. Install: G Starter motor yoke “1” G Starter motor front cover “2” G Starter motor rear cover “3” NOTE: Align the match marks on the starter motor yoke with the match marks on the starter motor front cover “a” and starter motor rear cover “b”.

R.2 ft • Ib) T. 5 3 6 4 10 Nm (1.2 ft • Ib) T.CLUTCH EAS25061 CLUTCH Removing the clutch cover 14 11 10 10 Nm (1. 7.0 m • kg.2 ft • Ib) 10 Nm (1. 8 7 9 12 13 14 10 Nm (1. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Brake pedal spring Water pump housing cover Gasket Oil cleaner element cover Oil cleaner element Cover Clutch cover Clutch cover gasket Dowel pin Crankcase cover (right) Crankcase cover right gascket Water pipe O-ring Dowel pin 1 1 1 1 1 1 1 1 2 1 1 1 1 2 Remove the clutch cover only if you do not remove the primary drive gear. 7. 5-34 . 7. Order Job/Parts to remove Drain the engine oil Drain the coolant Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on page 3-11. Refer to “CHANGING THE COOLANT” on page 3-18. Remove it from the frame mounting hook. T.2 ft • Ib) T. 1 R.0 m • kg. R. 2 R.0 m • kg.0 m • kg. 7.

CLUTCH Removing the clutch cover 14 11 10 10 Nm (1. reverse the removal procedure. R.0 m • kg.2 ft • Ib) T.0 m • kg. 5-35 . R.2 ft • Ib) T.2 ft • Ib) T. 7. 1 R. 5 3 6 4 10 Nm (1.0 m • kg.0 m • kg. 8 7 9 12 13 14 10 Nm (1. 7. T. 2 R. 7. 7. Order Job/Parts to remove Q’ty Remarks For installation.2 ft • Ib) 10 Nm (1.

4 E E 8 Nm (0. 54 ft • Ib) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 T.CLUTCH Removing the clutch 15 14 3 2 1(5) (5) T.8 m • kg.5 m • kg. 5. 75 Nm (7. 5. Job/Parts to remove 5-36 .8 ft • Ib) 8 Nm (0. reverse the removal procedure.8 m • kg.8 ft • Ib) R. 58 ft • Ib) 7 Q’ty 5 1 1 1 7 6 1 1 1 1 1 1 1 1 1 1 For installation.0 m • kg. R. Remarks Clutch spring Pressure plate Push rod Locknut Friction plate Clutch plate Primary drive gear nut Lock washer Clutch boss nut Lock washer Clutch boss Thrust washer Clutch housing Ball Clutch push rod Primary drive gear T. T. 13 12 11 10 9 6 5 E 16 8 80 Nm (8. R. R.

CLUTCH Removing the push lever shaft 1 3 10 Nm (1. 1 2 3 4 5 6 1 1 1 1 1 1 For installation.2 ft • Ib) T. 5-37 . R.0 m • kg. 7. reverse the removal procedure. 4 5 6 2 Order Job/Parts to remove Drive sprocket cover Clutch Clutch cable Clutch cable holder Push lever shaft Push lever spring Oil seal Bearing Q’ty Remarks Refer to “ENGINE REMOVAL” on page 5-1. Refer to “CLUTCH” on page 5-34.

3 a 2 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. loosen the clutch boss nut. Friction plate thickness 2. 4. 2.122 in) Limit 2. 2. Measure: G Clutch plate warpage (with a surface plate and thickness gauge “1”) Out of specification → Replace the clutch plates as a set.10 mm (0. Measure: G Friction plate thickness Out of specification → Replace the friction plates as a set.CLUTCH EAS25070 REMOVING THE CLUTCH You need not drain the coolant and engine oil if you do not service the primary drive gear. Check: G Friction plate 5-38 .114–0. Check: G Clutch plate Damage → Replace the clutch plates as a set.110 in) While holding the clutch boss “3” with the universal clutch holder “2”. 1. 1.10 mm (0. 1. and remove these parts by loosening the primary drive gear nut. Loosen: G Clutch boss nut “1” NOTE: Damage/wear → Replace the friction plates as a set. Remove: G Primary drive gear nut “1” G Lock washer NOTE: Insert aluminum plate “a” between primary drive gear “2” and clutch housing “3”. You can reach the clutch housing removal step by simply removing the cover and clutch cover. Universal clutch holder 90890-04086 YM-91042 1 2 EAS25110 3 3.90–3. Straighten the lock washer tab. Warpage limit 0.80 mm (0.0039 in) 1 EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. Straighten the lock washer tab. 2. NOTE: Measure the friction plate at four places.

Check: G Clutch housing dogs “a” Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing. Check: G Push rod “1” G Push rod “2” G Ball “3” Cracks/damage/wear → Replace.CLUTCH EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. NOTE: Pitting on the clutch boss splines will cause er- 5-39 . 1 3 2 Pitting on the clutch housing dogs will cause erratic clutch operation. 1. 2. Push rod bending limit 0. Check: G Clutch spring Damage → Replace the clutch springs as a set. Measure: G Push rod bending limit Out of specification → Replace the defective part (s).004 in) CHECKING THE CLUTCH BOSS 1.100 mm (0. EAS25170 CHECKING THE PRESSURE PLATE 1. Excessive noise during operation → Replace the primary drive and clutch housing as a set. Clutch spring free length 41. 2. Check: G Clutch boss splines Damage/pitting/wear → Replace the clutch boss.20 mm (1. a EAS25160 2. Check: G Pressure plate “1” Cracks/damage → Replace.54 in) ratic clutch operation. NOTE: CHECKING THE CLUTCH PUSH RODS 1. Check: G Primary driven gear Damage/wear → Replace the primary drive and clutch housing as a set. EAS25190 EAS25150 CHECKING THE CLUTCH HOUSING 1.62 in) Limit 39. Measure: G Clutch spring free length Out of specification → Replace the clutch springs as a set.14 mm (1.

Primary drive gear nut 80 Nm (8. Tighten: G Clutch boss nut “1” NOTE: 7 While holding the clutch boss “3” with the universal clutch holder “2”. the lock washer projection with the clutch boss slit during assembling. 6. Check: G Primary driven gear Damage/wear → Replace the primary drive and primary driven gears as a set. G Install the primary drive gear by facing its flat face toward the crankcase. and tighten the primary drive gear nut. Tighten: G Primary drive gear nut “1” NOTE: INSTALLING THE CLUTCH 1.CLUTCH EAS25200 CHECKING THE PRIMARY DRIVE GEAR 1. R. 54 ft•lb) 1 T. Bend the lock washer tab along a flat side of the nut. Lubricate: G Friction plates G Clutch plates (with the recommended lubricant) G Push rod G Push rod1 G Ball Recommended lubricant Engine oil 5-40 . Bend the lock washer tab along a flat side of the nut. tighten the clutch boss nut. 2 1 4 6 5 a 1 3 2. 4. 58 ft•lb) 3 2 T.0 m•kg. EAS25210 Universal clutch holder 90890-04086 YM-91042 Clutch boss nut 75 Nm (7. EAS25260 2 3 3. Check: G Primary drive gear Damage/wear → Replace the primary drive and primary driven gears as a set. Excessive noise during operation → Replace the primary drive and primary driven gears as a set. CHECKING THE PRIMARY DRIVEN GEAR 1.5 m•kg. Install: G Primary drive gear “1” G Clutch housing “2” G Thrust washer G Clutch boss “3” G Lock washer “4” New G Lock washer “5” New G Clutch boss nut “6” G Primary drive gear nut “7” NOTE: G Align Insert aluminum plate “a” between primary drive gear “2” and clutch housing “3”. 5. Excessive noise during operation → Replace the primary drive and primary driven gears as a set. R.

) 9. Lock nut 8 Nm (0. NOTE: Move the push lever in the arrow direction. the impeller shaft and check the engaging of impeller shaft gear and primary drive gear. install a friction plate and then alternate between a clutch plate and a friction plate. 1 2 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 13. Install: G Friction plates G Clutch plates NOTE: First.CLUTCH 7.8 m•kg.8 ft•lb) Tighten the clutch spring bolts in two stages and in a crisscross pattern. T.8 m•kg.Adjust: G Push lever position MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. and assemble the right crankcase cover.2 ft•lb) NOTE: G Tighten G Turn bolts in a crisscross pattern. and tighten the push rod locknut. Locknut 8 Nm (0. c. Install: G Push rod G Ball G Pressure plate G Clutch spring 10. b. 8.Tighten: G Push rod G Clutch spring NOTE: b a 12.Check: G Push lever position Push lever mark “a” and crankcase mark “b” not aligned → Correct. 5. 5. 5-41 . R. Install: G Push plate G Push rod (onto the clutch pressure plate.Install: G Water pipe “1” G O-ring “2” New G Dowel pin “3” G Crankcase cover right gascket “4” New G Crankcase cover (right) “5” Crankcase cover (right) bolt 10 Nm (1. Hold the push rod (not to move it). T. 5.8 ft•lb) Clutch spring bolt 8 Nm (0. and make sure that its movement becomes hard in the position where the marks match. R. R.8 ft•lb) 11. T.8 m•kg. 7. Return or tighten push rod “1” until the mark of push lever matches the mark of clutch cable holder.0 m•kg. Loosen locknut “2” of push rod “1”.

17.Install: G Oil cleaner element Refer to “CHANGING THE ENGINE OIL” on page 3-11.Fill: G Cooling system (with the specified amount of the the coolant) Refer to “CHANGING THE COOLANT” on page 3-18.Install: G Brake spring 5-42 .Fill: G Crankcase (with the specified amount of the engine oil) Refer to “CHANGING THE ENGINE OIL” on page 3-11. 18.CLUTCH New 5 3 4 3 1 2 New 14. 15.Install: G Water pump housing cover Refer to “WATER PUMP” on page 6-6. 16.

SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever LT 9 8 22 Nm (2. 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 For installation. 16 ft • Ib) T. reverse the removal procedure. 1 6 7 E 4 5 3 2 E E Job/Parts to remove Shift pedal Clutch housing Shift shaft Plate washer Stopper lever spring Circlip Plate washer Stopper lever Spacer Shift shaft spring Stopper screw Q’ty Remarks Refer to “ENGINE REMOVAL” on page 5-1. 5-43 . Refer to “CLUTCH” on page 5-34.2 m • kg. Order R.

SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: G Shift shaft G Shift lever Bends/damage/wear → Replace. Install: G Shift shaft “1” G Shift shaft spring “2” G Stopper lever “3” G Stopper lever spring NOTE: the ends “4” of the stopper lever spring onto the stopper lever and the crankcase boss. G Mesh the stopper lever with the shift drum segment assembly. EAS25450 INSTALLING THE SHIFT SHAFT 1. G Hook 5-44 . Check: G Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. G Shift lever spring Damage/wear → Replace. 2 4 1 3 EAS25430 CHECKING THE STOPPER LEVER 1.

Refer to“SHIFT SHAFT” on page 5-43. R. 5-45 .OIL PUMP AND BALANCER GEAR EAS24911 OIL PUMP AND BALANCER GEAR Removing the oil pump 8 9 13 10 12 7 4 11 5 6 2 1 3 10 Nm (1. 7.2 ft • Ib) 50 Nm (5. reverse the removal procedure. 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 1 1 1 1 1 2 1 1 1 2 For installation. T.0 m • kg. 36 ft • Ib) T. Order Job/Parts to remove Clutch/Primary drive gear Shift shaft Balancer weight gear nut Lock washer Balancer weight gear Straight key Absorber plate Balancer drive gear Straight key Circlip Plain washer Idle gear Gasket Oil pump assembly Dowel pin Q’ty Remarks Refer to“CLUTCH” on page 5-34. R.0 m • kg.

6 E 8 7 Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Pump cover Outer rotor Inner rotor Dowel pin Plain washer Driven gear Circlip Relief valve assembly Oil pump housing Q’ty 1 1 1 1 1 1 1 1 1 Remarks For installation. 1. 5-46 .2 m • kg.4 ft • Ib) T. reverse the removal procedure. R.OIL PUMP AND BALANCER GEAR Disassembling the oil pump 1 2 3 4 5 9 2 Nm (0.

Drain: G Engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” on page 3-11.0004–0. Lubricate: G Inner rotor G Outer rotor G Oil pump shaft (with the recommended lubricant) 5-47 . Remove: G Idle gear “1” G Oil pump assembly“2” 1 Inner-rotor-to-outer-rotor-tip clearance Less than 0. Measure: G Inner-rotor-to-outer-rotor-tip clearance “a” clearance G Outer-rotor-to-oil-pump-housing “b” G Oil-pump-housing-to-inner-rotor-and-outer-rotor clearance “c” Out of specification → Replace the oil pump.0012–0. 1.0013 in) Limit 0.0091 in) Oil-pump-housing-to-inner-rotor-and-outer-rotor clearance 0.120 mm (0.160 mm (0. Oil pump housing 3. Check: G Oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part (s). Check: G Oil pump drive gear G Oil pump driven gear G Oil pump housing G Oil pump housing cover Cracks/damage/wear → Replace the defective part (s).170 mm (0. EAS25000 ASSEMBLING THE OIL PUMP 1.0039 in) Limit 0.100 mm (0. 2.030–0.230 mm (0. Inner rotor 2.OIL PUMP AND BALANCER GEAR EAS24940 REMOVING THE OIL PUMP 1. 2.0047 in) Outer-rotor-to-oil-pump-housing clearance 0.0067 in) 2 3. Remove: G Balancer weight gear “1” G Balancer drive gear assembly “2” 1 2 EAS24960 CHECKING THE OIL PUMP 1.090–0. Outer rotor 3.

R. Install: G Drive gear “1” G Balancer weight gear “2” G Lock washer “3” New G Balancer weight gear nut “4” NOTE: 3. 36 ft•lb) T. Check: G Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-47.0 m•kg. EAS32D1008 INSTALLING THE OIL PUMP AND BALANCER GEAR 1. make sure the oil pump turns smoothly. R. Tighten: G Balancer weight gear nut “1” Blancer weight gear nut 50 Nm (5. Install: G Oil pump housing “1” G Relief valve assembly G Driven gear “2” G Dowel pin “3” G Outer rotor “4” G Inner rotor “5” G Oil pump cover Oil pump cover screw 2 Nm (0. 2. G Install the dowel pin on the spring as shown. 5-48 . Install: G Oil pump assembly Oil pump bolt 10 Nm (1.0 m•kg. NOTE: Insert aluminum plate “a” between drive gear “2” and balancer weight gear “3”. R.2 ft•lb) ECA13890 CAUTION: After tightening the bolts. 7. Install: G Drive gear “1” G Buffer boss “2” G Dowel pin “3” G Spring “4” (to driven gear) NOTE: mark “a” of the drive gear with slot “b” of the buffer boss. 1 2 3 Align mark “a” of the drive gear with mark “b” of the balancer shaft weight gear during assembling. 5. 4 5 1 a b 2 4 3 4.OIL PUMP AND BALANCER GEAR Recommended lubricant Engine oil 2. G Align T. 1. Tighten: G Primary drive gear nut Refer to “CLUTCH” on page 5-34. T.2 m•kg. and tighten the primary drive gear nut.4 ft•lb) 4 3 b a 3 4 2 3 4 1 3 4 3.

5-49 .OIL PUMP AND BALANCER GEAR 2 3 1 a 6. Install: Be sure to bend the lock washer tab along to the nut side face.

47 ft • Ib) T. Refer to “GENERAL CHASSIS” on page 4-1.5 m • kg.GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator 10 Nm (1. R.0 m • kg. 7. 1 2 3 4 5 6 7 8 9 10 11 12 13 Crankshaft position sensor coupler/Stator assembly coupler Timing mark accessing screw Crankshaft end cover Crankcase cover (left) Crankcase cover gascket (left) Dowel pin Stator assembly Damper assembly Starter idle gear shaft Starter idle gear Generator rotor Woodruff key Starter clutch gear 1/1 1 1 1 1 1 1 1 1 1 1 1 1 5-50 .2 ft • Ib) T.2 ft • Ib) R. R. Refer to “GENERAL CHASSIS” on page 4-1. 4 3 10 Nm (1. 8 1 9 10 LT E 13 12 15 LT 7 6 2 14 16 E 5 11 65 Nm (6. T. Order Job/Parts to remove Drain the engine oil Seat Air scoop (left) Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on page 3-11.0 m • kg. 7.

7.2 ft • Ib) R.GENERATOR AND STARTER CLUTCH Removing the generator 10 Nm (1. R. 7. 4 3 10 Nm (1.0 m • kg. 5-51 . T.0 m • kg. R.2 ft • Ib) T. Order 14 15 16 Job/Parts to remove Bearing Starter clutch side plate Starter clutch assembly Q’ty 1 1 1 Remarks For installation. 47 ft • Ib) T. reverse the removal procedure. 8 1 9 10 LT E 13 12 15 LT 7 6 2 14 16 E 5 11 65 Nm (6.5 m • kg.

reverse the removal procedure.GENERATOR AND STARTER CLUTCH Disassembling the damper assembly 6 5 4 3 2 1 M Order 1 2 3 4 5 6 Job/Parts to remove Circlip Limiter disc Starter reduction gear Limiter disc Outer torque limiter Circlip Q’ty 1 1 1 1 1 1 Remarks For installation. 5-52 .

4. G While 2 3 2. the starter clutch and the starter clutch drive gear should engage. Check the gear of the starter motor armature. Check: G Starter clutch idle gear G Starter clutch gear Burrs/chips/roughness/wear → Replace the defective part (s). When turning the starter clutch drive gear counterclockwise “B”. b. otherwise the starter clutch is faulty and must be replaced. otherwise the starter clutch is faulty and must be replaced. Check: G Starter clutch gear Damage/pitting/wear → Replace the starter clutch gear. G Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 1 2. c. Install the starter clutch drive gear “1” onto the starter clutch and hold the starter clutch. loosen the generator rotor nut.GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. a. Check: G Starter clutch rollers Damage/wear → Replace. Check: G Starter clutch operation MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM EAS24570 CHECKING THE STARTER CLUTCH 1. Remove: G Generator rotor “1” (with the rotor puller “2”) G Woodruff key Rotor puller 90890-04142 YM-04142 2 1 5. Remove: G Generator rotor nut “1” G Washer NOTE: holding the generator rotor “3” with the sheave holder “2”. it should turn freely. When turning the starter clutch drive gear clockwise “A”. Check: G Damper assembly Damage/pitting/wear → Replace the damper assembly. 3. 5-53 .

Install: G Starter idler gears 4. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 1 G While a 2 2.5 m•kg. 2. T. Install: G Woodruff key G Generator rotor G Washer G Generator rotor bolt 5-54 . 1 a 2 b Crankcase cover bolt 10 Nm (1. (Turn the projection part “a” to the interior side. G Do not allow the sheave holder to touch the projection on the generator rotor. G When installing the generator rotor. Install: G Starter clutch side plate “1” Set the 4 tabs “a” of the starter clutch side plate to the groove “b” of the generator rotor “2” securely. make sure the woodruff key is properly sealed in the keyway of the crankshaft. EAS24500 INSTALLING THE GENERATOR 1. tighten the generator rotor bolt. 7. 3 3. copper washer for part “2” only. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS24600 NOTE: INSTALLING THE STARTER CLUTCH 1.) 1 holding the generator rotor “3” with the sheave holder “2”.0 m•kg. R. Install: G Left crankcase cover “1” NOTE: G Tighten G Use R.GENERATOR AND STARTER CLUTCH NOTE: A B 1 the tapered portion of the crankshaft and the generator rotor hub.2 ft•lb) bolts in a crisscross pattern. Install: G Starter clutch assembly “1” Push the starter clutch assembly strongly until bumping. 47 ft•lb) G Clean T. Tighten: G Generator rotor nut “1” Generator rotor nut 65 Nm (6.

GENERATOR AND STARTER CLUTCH 2 1 5-55 .

2 ft • Ib) T.2 ft • Ib) T. 5 11 12 9 4 10 3 1 LT LT 6 2 LT 10 Nm (1.0 m • kg. 7. T. 8 LT 9 10 Nm (1. Refer to“STARTER MOTOR” on page 5-30. Order R. R. Refer to“SHIFT SHAFT” on page 5-43.2 ft • Ib) T. 1 2 3 4 5 6 7 Timing chain guide (intake side) Stopper guide plate Timing chain guide (exhaust side) Timing chain Speed sensor Neutral switch Delivery pipe 1 1 1 1 1 1 1 5-56 . Refer to“CYLINDER AND PISTON” on page 5-25. 7. 7.0 m • kg.9 ft • Ib) T.0 m • kg. R.CRANKCASE EAS25540 CRANKCASE Separating the crankcase 7 10 Nm (1.2 ft • Ib) LT 10 Nm (1.Balancer gear Generator rotor Q’ty Remarks Refer to“ENGINE REMOVAL” on page 5-1. Refer to“GENERATOR AND STARTER CLUTCH” on page 5-50. Refer to“OIL PUMP AND BALANCER GEAR” on page 5-45. R. R. Refer to“OIL PUMP AND BALANCER GEAR” on page 5-45. T. Job/Parts to remove Engine Cylinder head Cylinder Starter motor Clutch Balancer drive gear Shift shaft Oil pump. Refer to“CLUTCH” on page 5-34. Refer to“CYLINDER HEAD” on page 5-14. R.0 m • kg. 7.4 m • kg. 4 Nm (0.2 ft • Ib) 10 Nm (1. 2. 7.0 m • kg.

0 m • kg. R.2 ft • Ib) T. R. 8 LT 9 10 Nm (1. 2. Order 8 9 10 11 12 R.0 m • kg.CRANKCASE Separating the crankcase 7 10 Nm (1.0 m • kg. T.4 m • kg.2 ft • Ib) LT 10 Nm (1. 7. 7.2 ft • Ib) 10 Nm (1. R.2 ft • Ib) T.0 m • kg. R. R. reverse the removal procedure. T.2 ft • Ib) T. 7. 5 11 12 9 4 10 3 1 LT LT 6 2 LT 10 Nm (1. 4 Nm (0. Job/Parts to remove Crankcase Right Dowel pin Oil strainer Nozzle Left crankcase Q’ty 1 2 1 1 1 Remarks For installation. 5-57 .9 ft • Ib) T.0 m • kg. 7. 7.

0 m • kg. 7.2 ft • Ib) T.0 m • kg. LT 5 3 6 E 5 4 E LT 6 E E 10 Nm (1. reverse the removal procedure. R. 5-58 . R.CRANKCASE Removing the bearing and oil seal E 5 LT 2 5 1 10 Nm (1. Order Job/Parts to remove Crankshaft assembly Q’ty Remarks Refer to“CRANKSHAFT ASSEMBLY AND BALANCER SHAFT” on page 5-61. Refer to“TRANSMISSION” on page 5-64.2 ft • Ib) E T. 1 2 3 4 5 6 Transmission assembly Bearing cover plate Bearing cover plate Stopper plate Oil seal Bearing Needle bearing 1 2 2 2 7 2 For installation. 7.

CRANKCASE EAS25570 DISASSEMBLING THE CRANKCASE 1. 2. Thoroughly wash the crankcase halves in a mild solvent. EAS32D1015 G First ASSEMBLING THE CRANKCASE 1. 3. then remove the right crankcase. Check: G Nozzle G Delivery pipe Obstruction → Blow out with compressed air. 2.0 m•kg. 5-59 . EAS25700 CAUTION: check that the shift drum segment’s teeth and the drive axle circlip are properly positioned. R. Cracks/damage → Replace. 3. 7.0 m•kg. G Do not damage the crankcase mating surfaces. OIL STRAINER.2 ft•lb) LOCTITE® Oil delivery bolt 10 Nm (1. Check: G Timing chain guide Damage/wear → Replace. timing chain and crankshaft sprocket as a set. Turn: G Shift drum segment NOTE: 4. the shift drum segment’s teeth will not contact the crankcase during crankcase separation. remove them. NOZZLE. TIMING CHAIN GUIDE. Turn the shift drum segment to the position shown in the illustration. G Oil delivery passages Obstruction → Blow out with compressed air. in stages and in a crisscross pattern. Check: G Crankcase Cracks/damage → Replace. 2.0 m•kg. 7. CHECKING THE TIMING CHAIN. EAS25580 3. Check: G Oil strainer Obstruction → Blow out with compressed air. DELIVERY PIPE 1.2 ft•lb) LOCTITE® Oil strainer bolt 10 Nm (1. Thoroughly clean all the gasket surfaces and crankcase mating surfaces.2 ft•lb) LOCTITE® Bearing cover plate 10 Nm (1. Bends/cracks/damage → Replace. Check: G Timing chain Stiffness → Replace the camshaft sprocket. 7. 7. Remove: G Right crankcase ECA13910 CHECKING THE CRANKCASE 1. After all of the bolts are fully loosened.0 m•kg. Remove: G Crankcase bolts NOTE: Loosen each bolt 1/4 of a turn at a time. Install: G Nozzle “1” G Oil strainer “2” G Bearing cover plate “3” G Oil delivery pipe “4” Nozzle bolt 10 Nm (1.2 ft•lb) LOCTITE® T. In this position.

2 ft•lb) NOTE: the shift drum segment as shown so that the shift drum segment teeth do not contact the crankcase during its assembling.0 m•kg. M6 × 90 mm 2. with 1/4 turn each. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces. 5-60 . Apply: G Sealant (onto the crankcase mating surfaces) Yamaha bond No. M6 × 65 mm 3. Install: G Crankcase (to the left crankcase) Crankcase bolt 10 Nm (1. G Turn T. R. M6 × 45 mm 2 1 3 3 2 3 2 4. 1215 (Three Bond No.1215®) 90890-85505 2 1. 7. G Tighten the bolts in a crisscross pattern in two (2) stages.CRANKCASE 1 3 4 2 2. 3.

1 2 Job/Parts to remove Q’ty Remarks Separate. 5-61 .CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS25970 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT Removing the crankshaft assembly and balancer shaft 2 1 Order Crankcase. Balancer shaft Crankshaft assembly 1 1 For installation. reverse the removal procedure. Refer to“CRANKCASE” on page 5-56.

Measure: G Crankshaft width Out of specification → Replace the crankshaft.95–62. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B 3.0012 in) 4. crankshaft pin.CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS26000 REMOVING THE CRANKSHAFT ASSEMBLY 1. bearing or both. Width A 61.0138–0. or connecting rod.350–0. Check: G Crankshaft sprocket “1” Damage → Replace the crankshaft. Remove: G Crankshaft assembly “1” NOTE: G Remove the crankshaft assembly by using the crankcase separating tool “2”.00 mm (2. 1 2. EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1. NOTE: Turn the crankshaft slowly.441 in) EAS26060 CHECKING THE CRANKSHAFT ASSEMBLY 1. Runout limit C 0.0256 in) 5.650 mm (0.030 mm (0. Big end side clearance D 0. Install: G Crankshaft assembly NOTE: Install the crankshaft assembly with the crankshaft installer pot “1”. Check: G Crankshaft journal oil passage Obstruction → Blow out with compressed air. Measure: G Crankshaft runout Out of specification → Replace the crankshaft.439–2. crankshaft installer bolt 5-62 . Measure: G Big end side clearance Out of specification → Replace the big end bearing.

lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. 4 3 1 2 5-63 . adapter (M12) “3” and spacer “4”. NOTE: Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaft installer bolt until the crankshaft assembly bottoms against the bearing.CRANKSHAFT ASSEMBLY AND BALANCER SHAFT “2”. Crankshaft installer pot “1” 90890-01274 Installing pot YU-90058 Crankshaft installer bolt “2” 90890-01275 Bolt YU-90060 Adapter (M12) “3” 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) “4” 90890-04081 Pot spacer YM-91044 ECA13970 CAUTION: To avoid scratching the crankshaft and to ease the installation procedure.

5-64 .TRANSMISSION EAS26241 TRANSMISSION Removing the transmission. reverse the removal procedure. and shift forks 7 8 1 E 3 4 6 5 9 2 E E Order Crankcase 1 2 3 4 5 6 7 8 9 Job/Parts to remove Q’ty Remarks Separate. Shift fork guide bar Shift drum Shift fork-R Shift fork-C Shift fork-L Main axle assembly Drive axle assembly O-ring Collar 1 1 1 1 1 1 1 1 1 For installation. shift drum assembly. Refer to“CRANKCASE” on page 5-56.

TRANSMISSION Disassembling the transmission 7 6 5 4 3 M 8 2 1 M 9 10 12 11 13 14 15 16 M M 19 20 21 17 M 18 M 22 Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Job/Parts to remove 2nd pinion gear 6th pinion gear 3rd pinion gear Circlip Washer 5th pinion gear Main axle Circlip Plain washer 1st wheel gear Washer Collar 5th wheel gear Circlip Washer 4th wheel gear 3rd wheel gear 6th wheel gear Circlip Washer 2nd wheel gear 5-65 .

Remarks Order 22 Drive axle Job/Parts to remove 5-66 . reverse the removal procedure.TRANSMISSION Disassembling the transmission 7 6 5 4 3 M 8 2 1 M 9 10 12 11 13 14 15 16 M M 19 20 21 17 M 18 M 22 Q’ty 1 For installation.

TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. G Shift fork cam follower “1” CHECKING THE SHIFT DRUM ASSEMBLY 1. Bends → Replace.0032 in) 5-67 . CHECKING THE TRANSMISSION 1. G Shift drum bearing Damage/pitting → Replace the shift drum assembly. 3. Check: G Shift drum groove Damage/scratches/wear → Replace the shift drum assembly. Check: G Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. Main axle runout limit 0. 1. Check: G Shift fork pawl “2” Bends/damage/scoring/wear → Replace the shift fork. 2.08 mm (0. G Shift drum segment “1” Damage/wear → Replace the shift drum assembly. EWA12840 1 EAS26290 WARNING Do not attempt to straighten a bent shift fork guide bar. Measure: G Main axle runout (with a centering device and dial gauge “1”) Out of specification → Replace the main axle. Check: G Shift fork guide bar Roll the shift fork guide bar on a flat surface.

Drive axle runout limit 0. G Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear (s). 4 3.228–4. press the 2nd pinion gear “1” onto it “2” as shown. NOTE: 2 1 3 When reassembling the main axle. 4. Measure: G Drive axle runout (with a centering device and dial gauge “1”) Out of specification → Replace the drive axle.236 in) 2 5. a 1 a. 5-68 .6 mm (4. “C”.0032 in) EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1.08 mm (0. Install: G Shift fork guide bar “1” G Shift fork-R “2” G Shift fork-C “3” G Shift fork-L “4” NOTE: The embossed marks on the shift forks should face towards the clutch side of the engine and be in the following sequence: “R”. Check: G Transmission gear movement Rough movement → Replace the defective part (s).TRANSMISSION 2. Check: G Transmission gears Blue discoloration/pitting/wear → Replace the defective gear (s). “L”. Check: G Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 107.4–107.

NOTE: Oil each gear. Check: G Transmission Rough movement → Repair. and bearing thoroughly.TRANSMISSION EAS26340 INSTALLING THE TRANSMISSION 1. Install: G Transmission 2. 5-69 . shaft.

TRANSMISSION 5-70 .

.....................................................................................6-1 CHECKING THE RADIATOR..................................6-5 WATER PUMP ......................................6-6 CHECKING THE WATER PUMP..................................................................6-2 INSTALLING THE RADIATOR.......................6-4 CHECKING THE THERMOSTAT ............................................................6-7 ASSEMBLING THE WATER PUMP ............................................................................................................................................................................................................................................................................................6-2 THERMOSTAT.....6-5 INSTALLING THE THERMOSTAT ASSEMBLY ......................COOLING SYSTEM RADIATOR.....................6-7 1 2 3 4 5 6 7 8 9 .

6-1 . Disconnect. T. 7.2 ft • Ib) T. reverse the removal procedure. R.2 ft • Ib) T. Disconnect. For installation. 7 6 3 8 1 9 10 Nm (1. 7. R. Refer to“FUEL TANK” on page 7-1.0 m • kg.7 m • kg.4 ft • Ib) R.8 m • kg.0 m • kg. Order Job/Parts to remove Seat/Air scoop (left/right) Fuel tank Coolant Q’ty Remarks Refer to“GENERAL CHASSIS” on page 4-1. Disconnect.1 ft • Ib) 10 Nm (1. R. 1 2 3 4 5 6 7 8 9 10 Radiator fan motor coupler Radiator inlet hose Coolant reservoir hose Radiator outlet hose FID Hose (radiator side) Radiator cover Breather hose Recovery tank Radiator Radiator fan 1 1 1 1 1 1 1 1 1 1 Disconnect. 5. Disconnect. 2 Nm (0. T. 4 5 2 10 8 Nm (0.8 ft • Ib) T.RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0. Drain. R. 1.2 m • kg. 5. Refer to“CHANGING THE COOLANT” on page 3-18.

RADIATOR EAS26390 CHECKING THE RADIATOR 1. flat-head screwdriver. Fill: G Cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” on page 3-18.9 psi) (1. Apply the specified pressure for ten seconds and make sure there is no drop in pressure. Malfunction → Check and repair. Measure: G Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Radiator cap opening pressure 108. EAS26400 2.0–137. Attach the radiator cap tester “1” to the radiator. Check: G Radiator fan Damage → Replace.08–1. 3. Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 a. NOTE: Straighten any flattened fins with a thin. b. Check: G Cooling system Leakage → Collect or replace. Refer to “COOLING SYSTEM” on page 8-25. Check: G Radiator fins “1” Obstruction → Clean.37 kgf/cm2) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM INSTALLING THE RADIATOR 1. 2. Check: G Radiator hoses (IN/OUT) G Radiator pipes Cracks/damage → Replace. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. Apply compressed air to the rear of the radiator. Damage → Repair or replace. Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 6-2 .4 kPa (15.7–19. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Install the radiator cap tester “1” and radiator cap tester adapter “2” to the radiator cap “3”.

RADIATOR 1 b. Apply the 100 kPa (14. 6-3 . Refer to “CHECKING THE RADIATOR” on page 6-2. Measure the indicated pressure with the gauge.22 psi) (1. Measure: G Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. c.0 kg/cm2) pressure. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3.

Order Job/Parts to remove Seat/Air panel (left/right) Fuel tank Drains the coolant. Q’ty Remarks Refer to“GENERAL CHASSIS” on page 4-1. Disconnect. 7. Refer to“CHANGING THE COOLANT” on page 3-18. R. 1 2 3 4 Radiator inlet hose FID hose (thermostat side) Thermostat cover Thermostat 1 1 1 1 For installation. 1. Disconnect. reverse the removal procedure.2 ft • Ib) T. 6-4 . Refer to“FUEL TANK” on page 7-1. R.2 m • kg.THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 2 Nm (0.0 m • kg. 1 4 3 2 10 Nm (1.4 ft • Ib) T.

While stirring the water. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Install: G Thermostat “1” G Thermostat cover “2” NOTE: Install the thermostat by facing breather hole upward. 1 2 NOTE: If the accuracy of the thermostat is in doubt.3°F) → Replace. Check: G Cooling system Leaks → Repair or replace any faulty part. Place a thermometer “3” in the water “4”.5°C (158. Check: G Thermostat housing cover Cracks/damage → Replace. Slowly heat the water. 4.9–164. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 2. Refer to “CHECKING THE RADIATOR” on page 6-2. EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1. observe the thermostat and thermometer’s indicated temperature. c.2 ft•lb) 2. Thermostat cover bolt 10 Nm (1. A faulty thermostat could cause serious overheating or overcooling. Check: G Thermostat “1” Does not open at 70. A.0 m•kg. Measure: G Radiator cap opening pressure Below the specified pressure → Replace the radiator cap.5–73. 7. 6-5 . Fill: G Cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” on page 3-18. replace it.THERMOSTAT EAS26450 CHECKING THE THERMOSTAT 1. 3. Fully closed T. d. Suspend the thermostat “1” in a container “2” filled with water. b. R.

3 2 1 E LT Order Job/Parts to remove Drains the coolant.2 ft • Ib) T. 6-6 . Refer to“CHANGING THE ENGINE OIL” on page 3-11. Refer to“CLUTCH” on page 5-34.WATER PUMP EAS26500 WATER PUMP Removing the water pump 5 6 LT 7 4 10 Nm (1. 1 2 3 4 5 6 7 1 1 1 1 1 1 1 For installation. Refer to“CLUTCH” on page 5-34.0 m • kg. reverse the removal procedure. 7. R. Drains the engine oil Water pump housing cover Crank case cover light Circlips Impeller shaft gear Dowelpin Plate Impeller shaft Mechanical seal Bearing Q’ty Remarks Refer to“CHANGING THE COOLANT” on page 3-18.

7. R. 6-7 .2 ft•lb) T. Install: G Impeller shaft “1” G Plate “2” NOTE: 6. Check: G Impeller shaft gear Cracks/damage/chips → Replace.0 m•kg. Lubricate: G Mechanical seal lip G Impeller shaft 3. Check: G Water pump housing cover G Impeller shaft G Plate Cracks/damage/wear → Replace. Mechanical seal installer 90890-04145 Middle driven shaft bearing driver 90890-04058 4. Install: G Crankcase cover right gascket New G Crankcase cover (right) Refer to “CLUTCH” on page 5-34.2 ft•lb) 8.0 m•kg. Install: G Plate washer G Dowel pin G Impeller shaft gear “1” G Plate washer “2” G Circlip “3” New 1 2 3 3 2 1 2. Plate bolt 10 Nm (1. Tighten the plate bolt with appling the LOCTITE®. R. Lubricate: G Engine oil (to the bearing) 5. Install: G Bearing New G Mechanical “1” New (to the right crankcase cover) NOTE: G Install the mechanical seal by facing stamp world “WATER SIDE” to the impeller housing cover. Install: G Water pump housing cover gascket New G Water pump housing cover “1” (Bolt “2” with new copper washer) Water pump housing cover bolt 10 Nm (1. 7. 7.WATER PUMP EAS26530 CHECKING THE WATER PUMP 1. EAS26560 1 2 ASSEMBLING THE WATER PUMP 1. Fill: 1 2 T. G Install the mechanical seal by using mechanical seal installer “2” and middle driven shaft bearing driver “3”. 2.

WATER PUMP Crankcase Refer to “CHANGING THE ENGINE OIL” on page 3-11. G 6-8 . 9. Fill: G Cooling system Refer to “CHANGING THE COOLANT” on page 3-18.

WATER PUMP 6-9 .

..........................................................................7-2 INSTALLING THE FUEL TANK ....7-9 CHECKING THE AIR INDUCTION SYSTEM ............................7-6 ADJUSTING THE THROTTLE POSITION SENSOR .................7-4 CHECKING THE INJECTORS......................FUEL SYSTEM FUEL TANK ................7-2 REMOVING THE FUEL PUMP ...................................................7-2 THROTTLE BODIES...............................................................................7-1 REMOVING THE FUEL TANK...........7-6 CHECKING THE PRESSURE REGULATOR OPERATION........................................................................................7-13 1 2 3 4 5 6 7 8 9 .............................................................................................................................................................7-6 CHECKING THE PRESSURE REGULATOR ....................................................7-7 AIR INDUCTION SYSTEM..................................................................................7-12 CANISTER (FOR CALIFORNIA)........................................................................7-6 CHECKING THE THROTTLE BODIES............................7-2 INSTALLING THE FUEL PUMP..................................................

1 ft • Ib) 10 Nm (1. 10 Nm (1. 5. R. R. 5. reverse the removal procedure. 5. 1 2 3 4 5 6 7 1 1 1 1/1 1 1 1 Disconnect.1 ft • Ib) T. 7 R.7 m • kg.0 m • kg.4 m • kg. 4 4 1 3 6 4 Nm (0. 7-1 .7 m • kg. 7.0 m • kg.FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 7 Nm (0. Disconnect (for California) For installation. R. R.1 ft • Ib) 7 Nm (0. R. 2. 5 2 Job/Parts to remove Seat Side cover (left/right) Air scoop (left/right) Fuel tank Fuel hose coupler Hose (fuel tank-roll over valve) Fuel tank bracket (front/rear) Fuel pump bracket Fuel pump assembly O-ring Q’ty Remarks Refer to“GENERAL CHASSIS” on page 4-1.7 m • kg. T. 7 Nm (0. T. 7.9 ft • Ib) T.2 ft • Ib) T.2 ft • Ib) Order T.

G Before removing the fuel hose.4 m•kg. make sure that it is securely connected. Install: G Fuel pump Fuel pump bolts 4 Nm (0. place a few rags in the area under where it will be removed. and that the fuel hose holders are in the correct position. EAS26640 CAUTION: REMOVING THE FUEL PUMP 1. Remove: G Fuel tank NOTE: INSTALLING THE FUEL TANK 1. G Install the fuel pump as shown in the illustration. G Do the fuel hose on the fuel pipe until you hear a definite “click”. G Do not touch the base section of the fuel sender. Extract the fuel in the fuel tank through the fuel tank cap with a pump. Install: G Fuel hose G Fuel return hose ECA14740 Do not set the fuel tank down so that the installation surface of the fuel pump is directly under the tank. G Insert 7-2 . G Slide the fuel hose connector cover “1” at the fuel hose end in the direction of the arrow.FUEL TANK EAS26630 EAS26700 REMOVING THE FUEL TANK 1. R. G Align the slot “b” on the fuel tank damper with the projection “a” on the fuel pump. G Disconnecting the hose is done by hand. otherwise the fuel hose will not be properly installed. There is no need to use tools. and press the buttons “2” on both sides of the connector to remove the fuel hose. Remove: G Fuel pump ECA14720 When installing the fuel hose. 2.9 ft•lb) T. G Align the projection “a” on the fuel pump with the slot in the fuel pump bracket. G Slide not damage the installation surfaces of the fuel tank when installing the fuel pump. Remove: G Fuel hose coupler ECA14700 INSTALLING THE FUEL PUMP 1. Be sure to lean the fuel tank in an upright position. since there may be fuel remaining in it. G Always use a new fuel pump gasket. G Do a 2 1 b EAS32D1016 3. NOTE: CAUTION: not drop the fuel pump or give it a strong shock. 2. CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses. G Tighten the fuel pump bolts in stages in a crisscross pattern. NOTE: NOTE: the fuel hose connector cover “1” in the direction of the arrow mark.

FUEL TANK 1 7-3 .

Refer to “CAMSHAFT” on page 5-6. Drain. Disconnect. 7-4 . Refer to “CAMSHAFT” on page 5-6. reverse the removal procedure. Refer to “CHANGING THE COOLANT” on page 3-18. Side cover (left/right) Air scoop (left/right) Fuel tank Throttle cable Clutch cable Coolant Ignition coil lead Injector coupler Vacuum hose ITS boost hose FID hose (Thermostat side/radiator side) Hose (canister-throttle body) Throttle bodies assembly Refer to “FUEL TANK” on page 7-1.THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 1 4 3 2 4 6 5 Order Seat Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page 4-1. 1 2 3 4 5 6 1 1 1 2 1 1 (for California) For installation.

THROTTLE BODIES Disassembling the throttle body 3. 2.4 m • kg. 7-5 .5 ft • Ib) T. reverse the removal procedure. 3. 2 3 1 4 5 Nm (0.5 m • kg.6 ft • Ib) T. Order 1 2 3 4 Job/Parts to remove Delivery pipe Injector Gasket Throttle position sensor Q’ty 1 1 1 1 Remarks For installation. R.5 Nm (0. R.

Measure the fuel pressure. Check: G Pressure regulator operation LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 7-6 . Wash the throttle bodies in a petroleumbased solvent.50 kg/cm2) f. Start the engine. The vacuum pressure should not exceed 100 kPa (14. Check: G Injectors Damage → Replace. b.00 kg/cm2). 1. EAS26990 a. Use the vacuum/pressure pump gauge set to adjust the fuel pressure in relation to the vacuum pressure as described below. Connect the pressure gauge “1” and adapter “2” to the fuel injection pipe. e. 1.THROTTLE BODIES EAS26980 CHECKING THE INJECTORS EWA32D1009 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM WARNING Replace the fuel injector with a new one if you have dropped or impacted it. Remove the fuel tank. Refer to “FUEL TANK” on page 7-1. Increase the vacuum pressure → Fuel pressure is decreased Decrease the vacuum pressure → Fuel pressure is increased Faulty → Replace the pressure regulator. EAS27010 CHECKING THE PRESSURE REGULATOR OPERATION 1. Refer to “FUEL TANK” on page 7-1. 2. Install the fuel tank. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. b. Fuel pressure 250 kPa (35. NOTE: Replace the pressure regulator with a new one if you have dropped or impacted it. Check: G Throttle bodies Cracks/damage → Replace the throttle bodies as a set. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS27000  CHECKING THE PRESSURE REGULATOR EWA32D1010 WARNING c. Do not use any caustic carburetor cleaning solution. Check: G Fuel passages Obstructions → Clean. Vacuum/pressure pump gauge set 90890-06756 Mityvac brake bleeding tool YS-42423 Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03176 YM-03176 CHECKING THE THROTTLE BODIES 1.6 psi) (2. d.2 psi) (1. Blow out all of the passages with compressed air. Check: G Pressure regulator Damage → Replace.

After adjusting the throttle position sensor an- 7-7 . d.73 V e. Adjust the throttle position sensor angle so that the voltage is within the specified range. Positive tester probe Blue “1” Negative tester probe Black/Blue “2” Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 L Y B/L 1 2 c.THROTTLE BODIES EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR EWA32D1011 gle. Connect the throttle position sensor coupler to the wire harness. 2. Adjust: G Throttle position sensor angle MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Measure the throttle position sensor voltage. tighten the throttle position sensor screws. the engine idling speed should be properly adjusted. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL WARNING Replace the throttle position sensor with a new one if you have dropped or impacted it. Throttle position sensor Output voltage (when the engine is idling) 0. NOTE: Before adjusting the throttle position sensor.63–0. Check: G Throttle position sensor Refer to “CHECKING THE THROTTLE POSITION SENSOR” on page 8-79. 1. b. Connect the digital circuit tester to the throttle position sensor.

THROTTLE BODIES 7-8 .

AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 1 2 3 4 7-9 .

Air induction system hose 3. Air induction system pipe 7-10 . Air filter case 2. Air cut-off valve 4.AIR INDUCTION SYSTEM 1.

6 4 2 T. For installation.0 m • kg. 1 R. 7. 7.0 m • kg. Disconnect. reverse the removal procedure. 3 5 Job/Parts to remove Seat Side cover (left/right) Air scoop (left/right) Fuel tank Air induction coupler Air induction system pipe Gasket Pipe3 Air induction system hose Air cut-off valve assembly Q’ty Remarks Refer to“GENERAL CHASSIS” on page 4-1. 7-11 . Order R.2 ft • Ib) T.2 ft • Ib) 10 Nm (1.AIR INDUCTION SYSTEM Removing the air cut-off valve assembly 10 Nm (1. 1 2 3 4 5 6 1 1 1 1 1 1 Refer to“FUEL TANK” on page 7-1.

7-12 . Check: G Reed valve G Reed valve stopper G Reed valve seat Cracks/damage → Replace the reed valve. Check: G Air cut-off valve Cracks/damage → Replace. reducing the emission of hydrocarbons. allowing secondary air to flow into the exhaust port. Cracks/damage → Replace. 2. When there is negative pressure at the exhaust port. Air cut-off valve The air cut-off valve is controlled by the signals from the ECU in accordance with the combustion conditions. A B A. the reed valve opens. G Pipes Cracks/damage → Replace. To the cylinder head 1. Ordinarily. the air cut-off valve opens to allow the air to flow during idle and closes to cut-off the flow when the vehicle is being driven.AIR INDUCTION SYSTEM EAS27060 CHECKING THE AIR INDUCTION SYSTEM Air induction The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port. 3. The required temperature for burning the unburned exhaust gases is approximately 600 to 700°C. From the air filter B. Check: G Hoses Loose connections → Connect properly.

2 ft • Ib) 5 6 Order 1 2 3 4 5 6 T.0 m • kg. Job/Parts to remove Canister cover Canister Hose (fuel tank–roll over valve) Roll over valve Hose (roll over valve–canister) Hose (canister–throttle body) Q’ty 1 1 1 1 1 1 Remarks For installation. R.AIR INDUCTION SYSTEM EAS32D12011 CANISTER (FOR CALIFORNIA) Removing the canister 3 4 10 Nm (1. R. 7. 7. 7-13 . reverse the removal procedure.2 ft • Ib) T. 2 1 10 Nm (1.0 m • kg.

..........................................................................................................................................8-15 CIRCUIT DIAGRAM ..............8-15 TROUBLESHOOTING .8-68 CHECKING THE RELAYS .........................................................................................................................................................................................................8-25 CIRCUIT DIAGRAM .........8-31 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) ...........................................................................................................................................................................................................................................8-19 CIRCUIT DIAGRAM ...........8-55 TROUBLE SHOOTING ............................................................................................ELECTRICAL SYSTEM IGNITION SYSTEM ..............8-11 TROUBLESHOOTING .................................8-9 CHARGING SYSTEM ...8-34 TROUBLESHOOTING DETAILS ...............................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION...............................................................................8-71 CHECKING THE DIODE...........................................................................8-74 1 2 3 4 5 6 7 8 9 .................................................................................................................................8-67 CHECKING AND CHARGING THE BATTERY......8-29 CIRCUIT DIAGRAM ...................................................................................................................................8-21 COOLING SYSTEM ....................8-1 TROUBLESHOOTING ..............................................................8-74 CHECKING THE IGNITION COIL...............8-29 ECU SELF-DIAGNOSTIC FUNCTION.................................................................................8-19 TROUBLESHOOTING ...........................................................................................................................................................................................8-1 CIRCUIT DIAGRAM ...........................8-5 CIRCUIT DIAGRAM ................8-66 CHECKING THE FUSES ...........................................................................................................................................................................................................8-55 CIRCUIT DIAGRAM ............................8-17 SIGNALING SYSTEM ...........................................................8-11 CIRCUIT DIAGRAM ..........................................................8-3 ELECTRIC STARTING SYSTEM....8-63 CHECKING THE BULBS AND BULB SOCKETS .........................8-57 ELECTRICAL COMPONENTS ......................................................................................................................................................................8-73 CHECKING THE IGNITION SPARK GAP ...8-7 TROUBLESHOOTING ................................................................................................................................8-34 DIAGNOSTIC MODE .............................................................................................................................8-27 FUEL INJECTION SYSTEM ....................................................................8-41 FUEL PUMP SYSTEM ........................................8-59 CHECKING THE SWITCHES ..........8-32 TROUBLESHOOTING METHOD...............8-25 TROUBLESHOOTING .......................................................................................8-13 LIGHTING SYSTEM..................................................................................................

.........................................................................................................8-79 CHECKING THE THROTTLE POSITION SENSOR...........................................................8-75 CHECKING THE STATOR COIL ............................................................................................................................8-80 CHECKING THE INTAKE AIR TEMPERATURE SENSOR................................8-76 CHECKING THE RECTIFIER/REGULATOR....8-81 ......8-78 CHECKING THE COOLANT TEMPERATURE SENSOR ..........................8-78 CHECKING THE RADIATOR FAN MOTOR .......................8-77 CHECKING THE FUEL SENDER (FUEL PUMP) .............................8-80 CHECKING THE INTAKE SOLENOID................8-80 CHECKING THE INTAKE AIR PRESSURE SENSOR ....................8-79 CHECKING THE EXUP SERVO MOTOR .............................................8-76 CHECKING THE HORN.....................................8-75 CHECKING THE LEAN ANGLE SENSOR .............8-77 CHECKING THE SPEED SENSOR..............CHECKING THE CRANKSHAFT POSITION SENSOR ........................................

.

IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM 8-1 .

IGNITION SYSTEM 1. Spark plug 27. Battery 5. ECU 17. Main switch 4. Sidestand switch 13. Main fuse 8. Clutch switch 16. Lean angle sensor 56. Ignition fuse 8-2 . Relay unit 12. AC magneto 3. Neutral switch 14. Right handlebar switch 9. Ignition coil 18. Engine stop switch 11.

Check the neutral switch. Check the spark plug. NG→ Replace the ignition coil. OK↓ 9. Check the fuses. Check the crankshaft position sensor. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-68. NG↓ 5. Check the ignition spark gap. Refer to “CHECKING THE SWITCHES” on page 8-63. or replace the battery. OK↓ 7. NG→ Replace the stater assembly. NOTE: Before troubleshooting. Check the engine stop switch. Check the main switch. Seat 2. 8-3 . Check the battery. OK↓ 6. Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on page 8-75. Refer to “CHECKING THE SWITCHES” on page 8-63. NG→ Replace the right handlebar switch. OK↓ NG→ Replace the neutral switch. remove the following part (s): 1. OK↓ 3. Refer to “CHECKING THE IGNITION SPARK GAP” on page 8-74. Air scoop (left/right) 4. NG→ Replace the main switch. OK→ The ignition system is normal. Fuel tank 1. NG→ Replace the fuse (s). Check the ignition coil. NG→ GClean GRecharge the battery terminals. (Main and ignition) Refer to “CHECKING THE FUSES” on page 8-67. OK↓ 8. NG→ Re-gap or replace the spark plug. Side cover (left) 3.IGNITION SYSTEM EAS27130 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). OK↓ 2. Refer to “CHECKING THE SWITCHES” on page 8-63. Refer to “CHECKING THE SPARK PLUG” on page 3-8. Refer to “CHECKING THE IGNITION COIL” on page 8-74. OK↓ 4.

Check the diode. NG→ Replace the sidestand switch. Refer to “CHECKING THE RELAYS” on page 8-71. OK↓ 14.Check the relay unit. NG→ Replace the relay unit.Check the sidestand switch.Check the entire ignition system’s wiring. NG→ Replace the lean angle sensor. Refer to “CIRCUIT DIAGRAM” on page 8-1. OK↓ 11. OK↓ 12. OK↓ Replace the ECU. Refer to “CHECKING THE SWITCHES” on page 8-63. NG→ Replace the relay unit. OK↓ 13. OK↓ 15. NG→ Properly connect or repair the ignition system’s wiring.IGNITION SYSTEM 10.Check the clutch switch. 8-4 . Refer to “CHECKING THE LEAN ANGLE SENSOR” on page 8-75. Refer to “CHECKING THE SWITCHES” on page 8-63.Check the lean angle sensor. Refer to “CHECKING THE DIODE” on page 8-73. NG→ Replace the clutch switch.

ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM 8-5 .

Engine stop switch 10. Right handlebar switch 9.ELECTRIC STARTING SYSTEM 3. Ignition fuse 8-6 . Battery 5. Main fuse 6. Relay unit 12. Starter relay 7. Start switch 11. Signaling system fuse 56. Main switch 4. Starter motor 8. Neutral switch 14. Sidestand switch 13. Clutch switch 55.

the starting circuit cut-off relay is open so current cannot reach the starter motor. G The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed). 15 14 1 8 2 7 3 4 5 6 13 a 9 9 9 10 b 11 12 8-7 . In this instance. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. the starter motor can only operate if at least one of the following conditions is met: G The transmission is in neutral (the neutral switch is closed).

Signal fuse 8. Diode 10. Starter relay 15. Engine stop switch 6. Ignition fuse 5. Starting circuit cut-off relay 7. Neutral switch 13. Battery 2. Diode 9. WHEN THE TRANSMISSION IS IN NEUTRAL b. Main fuse 3. Start switch 14. Clutch switch 11. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Main switch 4. Sidestand switch 12.ELECTRIC STARTING SYSTEM a. Starter motor 8-8 .

Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-68. NG→ Replace the starter relay. Refer to “CHECKING THE RELAYS” on page 8-71. OK↓ 5. or replace the battery. OK↓ 9. Check the battery. OK↓ 7. 8-9 . Seat 2. Check the fuses. Check the relay unit.Check the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 8-63. Check the neutral switch. NG→ Repair or replace the starter motor. Air scoop (left/right) 4.ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. Refer to “CHECKING THE STARTER MOTOR” on page 5-32. OK↓ 8. (Main. the battery terminals. Check the engine stop switch. Refer to “CHECKING THE SWITCHES” on page 8-63. Check the starter relay. OK↓ 2. Check the diode. NOTE: Before troubleshooting. Side cover (left) 3. OK↓ 6. OK↓ 10. OK↓ 4. NG→ Replace the right handlebar switch. Refer to “CHECKING THE RELAYS” on page 8-71. NG→ Replace the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 8-63. ignition and signal fuse) Refer to “CHECKING THE FUSES” on page 8-67. Fuel tank 1. remove the following part (s): 1. NG→ Replace the relay unit. NG→ Replace the relay unit. Check the main switch. NG→ Replace the neutral switch. Refer to “CHECKING THE SWITCHES” on page 8-63. NG→ GClean GRecharge NG→ Replace the fuse (s). OK↓ 3. NG→ Replace the main switch. Replace the starter motor. Refer to “CHECKING THE DIODE” on page 8-73.

OK↓ The starting system circuit is OK.Check the clutch switch. 8-10 .Check the entire starting system’s wiring.ELECTRIC STARTING SYSTEM OK↓ 11. Refer to “CHECKING THE SWITCHES” on page 8-63. NG→ Properly connect or repair the starting system’s wiring. NG→ Replace the right handlebar switch. OK↓ 13. Refer to “CHECKING THE SWITCHES” on page 8-63. Refer to “CIRCUIT DIAGRAM” on page 8-5.Check the start switch. NG→ Replace the clutch switch. OK↓ 12.

CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11 .

AC magneto Rectifier/regulator Battery Main fuse 8-12 . 5.CHARGING SYSTEM 1. 4. 2.

Seat 2. remove the following part (s): 1. NG→ Properly connect or repair the charging system’s wiring. Check the battery. Check the fuse. Refer to “CIRCUIT DIAGRAM” on page 8-11. Check the stator coil. NOTE: Before troubleshooting. OK↓ 2. Air scoop (left) 1. (Main) Refer to “CHECKING THE FUSES” on page 8-67. Check the entire charging system’s wiring. 8-13 . Refer to “CHECKING THE RECTIFIER/REGULATOR” on page 8-76.CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. or replace the battery. Check the rectifier/regulator. Side cover (left) 3. NG→ GClean GRecharge NG→ Replace the fuse. the battery terminals. OK↓ 3. NG→ Replace the stator assembly. OK↓ This circuit is OK. OK↓ 5. Refer to “CHECKING THE STATOR COIL” on page 8-76. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-68. NG→ Replace the rectifier/regulator. OK↓ 4.

CHARGING SYSTEM 8-14 .

LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15 .

Front right turn signal/position light 40. High beam indicator 39. Headlight 50. Main switch 4. Dimmer switch 44. Signaling system fuse 8-16 . Tail/brake light 51. Headlight fuse 55. Battery 5. ECU 34. Headlight relay 43. Front left turn signal/position light 42. Main fuse 16.LIGHTING SYSTEM 3. License light 54.

OK↓ Replace the ECU. Air scoop (left/right) 4. Refer to “CHECKING THE SWITCHES” on page 8-63.LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight. NOTE: Before troubleshooting. NG→ Replace the bulb (s) and bulb socket (s). OK↓ 6. OK↓ 2. NG→ Replace the left handlebar switch. Check the dimmer switch. Refer to “CHECKING THE RELAYS” on page 8-71. Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 8-66. Refer to “CHECKING THE SWITCHES” on page 8-63. Fuel tank 1. OK↓ 7. Check the entire lighting system’s wiring. or replace the battery. Seat 2. high beam indicator light. NG→ Replace the main switch. remove the following part (s): 1. NG→ GClean GRecharge NG→ Replace the fuse (s). Check the headlight relay. OK↓ 3. (Main. 8-17 . Check the fuses. Check the each bulbs and bulb sockets condition. OK↓ 4. taillight. Refer to “CIRCUIT DIAGRAM” on page 8-15. NG→ Replace the headlight relay. headlight and signal) Refer to “CHECKING THE FUSES” on page 8-67. the battery terminals. Check the battery. Check the main switch. NG→ Properly connect or repair the lighting system’s wiring. license light or meter light. OK↓ 5. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-68. Side cover (left) 3.

LIGHTING SYSTEM 8-18 .

SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19 .

SIGNALING SYSTEM
3. Main switch 4. Battery 5. Main fuse 11. Relay unit 13. Neutral switch 15. Fuel pump 16. ECU 23. Coolant temperature sensor 24. Speed sensor 30. Neutral indicator light 31. Coolant temperature warning light 33. Fuel level warning light 35. Turn signal indicator light 36. Turn signal relay 37. Turn signal switch 38. Rear right turn signal light 39. Front right turn signal/position light 40. Front left turn signal/position light 41. Rear left turn signal light 45. Horn 46. Horn switch 47. Left handlebar switch 48. Rear brake switch 49. Front brake switch 50. Tail/brake light 54. Headlight fuse 55. Signaling system fuse 56. Ignition fuse

8-20

SIGNALING SYSTEM
EAS27290

TROUBLESHOOTING G Any of the following fail to light: turn signal light, brake light, turn signal indicator light and fuel level warning light. G The horn fails to sound. G The speedometer does not operate normally. G The fuel indicator light does not come on. G The coolant temperature warning light does not operate normally.
NOTE:

Before troubleshooting, remove the following part (s): 1. Seat 2. Side cover (left) 3. Air scoop (left/right) 4. Fuel tank

.
1. Check the fuses. (Main, ignition, signaling and headlight) Refer to “CHECKING THE FUSES” on page 8-67. OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-68. OK↓ 3. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 8-63. OK↓ 4. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-19. OK↓ This circuit is OK. Check the signaling system The horn fails to sound. 1. Check the horn switch. Refer to “CHECKING THE SWITCHES” on page 8-63. OK↓ 2. Check the horn. Refer to “CHECKING THE HORN” on page 8-77. OK↓ 3. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-19. OK↓ NG→ Properly connect or repair the signaling system’s wiring. NG→ Replace the horn. NG→ Replace the left handlebar switch. NG→ Properly connect or repair the signaling system’s wiring. NG→ Replace the main switch. NG→
GClean GRecharge

NG→

Replace the fuse (s).

the battery terminals. or replace the battery.

8-21

SIGNALING SYSTEM
This circuit is OK. The brake light fails to come on. 1. Check the front brake light switch. Refer to “CHECKING THE SWITCHES” on page 8-63. OK↓ 2. Check the rear brake light switch. Refer to “CHECKING THE SWITCHES” on page 8-63. OK↓ 3. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-19. OK↓ Replace the tail/brake light. The turn signal light, turn signal indicator light or both fail to blink. 1. Check the turn signal light bulb and socket. Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 8-66. OK↓ 2. Check the turn signal switch. Refer to “CHECKING THE SWITCHES” on page 8-63. OK↓ 3. Check the turn signal relay. Refer to “CHECKING THE RELAYS” on page 8-71. OK↓ 4. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-19. OK↓ Replace the meter assembly. The neutral indicator light fails to come. 1. Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 8-63. OK↓ 2. Check the diode. Refer to “CHECKING THE DIODE” on page 8-73. OK↓ NG→ Replace the relay unit (Starting circuit cut-off relay). NG→ Replace the neutral switch. NG→ Properly connect or repair the signaling system’s wiring. NG→ The turn signal relay is faulty and must be replaced. NG→ Replace the left handlebar switch. NG→ Replace the turn signal light bulb, socket or both. NG→ Properly connect or repair the signaling system’s wiring. NG→ Replace the rear brake light switch. NG→ Replace the front brake light switch.

8-22

SIGNALING SYSTEM
3. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-19. OK↓ Replace the meter assembly. The speedometer fails to operate.
1. Check the speed sensor. Refer to “CHECKING THE SPEED SENSOR” on page 8-77.

NG→

Properly connect or repair the signaling system’s wiring.

NG→

Replace the speed sensor.

OK↓ 2. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-19. OK↓ Replace the meter assembly. The fuel level warning light fails to come. 1. Check the fuel sender. Refer to “CHECKING THE FUEL
SENDER (FUEL PUMP)” on page 8-78.

NG→

Properly connect or repair the signaling system’s wiring.

NG→

Replace the fuel pump assembly.

OK↓ 2. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-19. OK↓ Replace the meter assembly. The coolant temperature warning light fails to operate.
1. Check the coolant temperature sen-

NG→

Properly connect or repair the signaling system’s wiring.

sor. Refer to “CHECKING THE COOLANT
TEMPERATURE SENSOR” on page 8-78.

NG→

Replace the coolant temperature sensor.

OK↓ 2. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-19. OK↓ Replace the meter, ECU or both. NG→ Properly connect or repair the signaling system’s wiring.

8-23

SIGNALING SYSTEM

8-24

COOLING SYSTEM
EAS27300

COOLING SYSTEM
EAS27310

CIRCUIT DIAGRAM

8-25

COOLING SYSTEM
3. Main switch 4. Battery 5. Main fuse 16. ECU 23. Coolant temperature sensor 52. Radiator fan motor relay 53. Radiator fan motor 56. Ignition fuse 57. Radiator fan fuse

8-26

Refer to “CHECKING THE SWITCHES” on page 8-63. ignition and radiator fan fuse) Refer to “CHECKING THE FUSES” on page 8-67. Check the coolant temperature. Seat 2. NG→ the battery terminals. OK↓ 6. NOTE: Before troubleshooting. Drain the coolant. OK↓ 2. Fuel tank 5. 1. OK↓ 3. NG→ The radiator fan motor is faulty and must be replaced. Check the battery. Check the radiator fan motor relay. OK↓ 5. Side cover (left) 3. NG→ Replace the fuse (s). Refer to “CHECKING THE RADIATOR FAN MOTOR” on page 8-79. NG→ Properly connect or repair the cooling system’s wiring. (Main. 8-27 . NG→ Replace the coolant temperature sensor. Check the fuses. OK↓ 4. OK↓ Replace the ECU. Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR” on page 8-78. OK↓ 7. NG→ Replace the radiator fan motor relay. Air scoop (left/right) 4. remove the following part (s): 1. Check the entire cooling system’s wiring.COOLING SYSTEM EAS27320 TROUBLESHOOTING G The radiator fan fails to operate. Check the radiator fan motor. Refer to “CHECKING THE RELAYS” on page 8-71. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-68. Radiator cover 6. GClean NG→ Replace the main switch. Refer to “CIRCUIT DIAGRAM” on page 8-25. GRecharge or replace the battery. Check the main switch.

COOLING SYSTEM 8-28 .

FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29 .

Headlight relay 52. Main switch 4. ECU 17. Right handlebar switch 9. Start switch 11. Fuel pump 16. Relay unit 12. Clutch switch 15. Throttle position sensor 26. ITS solenoid 20. AI solenoid 22. Signaling system fuse 56. Engine trouble warning light 42. EXUP servo motor 32. AC magneto 3. Radiator fan motor relay 54. Lean angle sensor 28. Ignition fuse 58. Spark plug 19. Backup fuse 8-30 . Neutral switch 14. Engine stop switch 10. Ignition coil 18. Intake air temperature sensor 23. Starter relay 8. Intake air pressure sensor 27. Speed sensor 25. Main fuse 6. Headlight fuse 55. Coolant temperature sensor 24.FUEL INJECTION SYSTEM 1. Fuel injector 21. Sidestand switch 13. EFI fuse 59. Battery 5.

the ECU provides an appropriate substitute characteristic operation. it remains stored in the memory of the ECU until it is deleted. Engine trouble warning light indication and FI system operation Warning light indication Flashing* ECU operation Warning provided when unable to start engine Malfunction detected FI operation Operation stopped Operated with substitute characteristics in accordance with the description of the malfunction Vehicle operation Cannot be operated Can or cannot be operated depending on the fault code Remains on * The warning light flashes when any one of the conditions listed below is present and the start switch is pushed: 12: 19: 30: 33: Crankshaft position sensor Sidestand switch (open circuit in the wire to the ECU) Lean angle sensor (Latch up detected) Ignition coil (Malfunction detected in the primary wire of the ignition coil) 41: 50: Lean angle sensor (open or short-circuit) ECU internal malfunction (faulty ECU memory) Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1. a c b d c a. Main switch OFF Main switch ON Light OFF Light ON for 1.FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally.4 seconds after the main switch has been turned to “ON” and when the start switch is being pushed. it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. the engine trouble warning light flashes when the start switch is being pushed to start the engine. If this function detects a malfunction in the system. a fault code is stored in the memory of the ECU. the warning light bulb may be defective. the lowest fault code number appears on the clock LCD. c. Once a fault code has been displayed. d. If the warning light does not come on under these conditions. b. G After the engine has been stopped. and alerts the rider of the detected malfunction by illuminating the engine trouble warning light. G If a malfunction is detected in the system by the self-diagnostic function.4 seconds 8-31 . G To inform the rider that the fuel injection system is not functioning. Once a malfunction has been detected.

EXUP servo motor is stuck. Coolant temperature sensor-open or short circuit detected. Intake air temperature sensor-open or short circuit detected. The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value. Lean angle sensor-open or short circuit detected. Intake air pressure sensor (open or short circuit) Intake air pressure sensor (pipe system) Throttle position sensor (open or short circuit) Throttle position sensor (stuck) EXUP servo motor circuit (open or short-circuit) EXUP servomotor (stuck) Sidestand switch (open circuit wire harness to ECU) Coolant temperature sensor Intake air temperature sensor Lean angle sensor Ignition coil (faulty ignition) Lean angle sensor (open or short circuit) Speed sensor Intake air pressure sensor-open or short circuit detected. Malfunction detected in the primary wire of the ignition coil. the ECU illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction. Self-Diagnostic Function Fault code No. Open or short circuit is detected in the neutral switch. 14 15 16 17 18 19 21 22 30 33 41 Able Able Able Able Able Unable Able Able Unable Unable Unable Able Able Able Able Able Able Able Able Unable Able Able Unable Unable Unable Able Able Able 42 Neutral switch 43 Fuel system voltage (monitor voltage) 8-32 . EXUP servo motor circuit open or short circuit. Open circuit is detected in the input line from the sidestand switch to the ECU. and the other in which the ECU directly operates an actuator. The throttle position sensor is stuck. Details on the fail-safe actions are given in the table below. Intake air pressure sensor-pipe system malfunction (clogged or detached hose).No normal signals are received from sor the crankshaft position sensor.FUEL INJECTION SYSTEM EAS27393 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven. 12 13 Item Symptom Able / unable to start Unable Able Able / unable to drive Unable Able Crankshaft position sen. No normal signal is received from the lean angle sensor. No normal signals are received from the speed sensor. Latch up detected. depending on the conditions. Supply power to the fuel injector and fuel pump is not normal. the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating. When an abnormal signal is received from a sensor. Throttle position sensor-open or short circuit detected.

Er-2 Able* Able* Er-3 Able* Able* Er-4 Able* Able* * If multiple malfunctions have been detected for the ECU. Data from the ECU cannot be received correctly. Able Able 46 Able 50 Unable Unable 70 Able Able — Start unable warning Unable Unable Communication error with the multifunction meter Fault code No. No signals are received from the ECU within the specified duration. Power supply to the ECU system relay is not normal. Item Symptom Able / unable to start Able / unable to drive 44 Error in writing the amount of CO adjustment on EEPROM Vehicle system power supply (Monitor voltage) ECU internal malfunction (memory check error) Left idle control Error is detected while reading or writing on EEPROM (code re-registering Able key code and throttle valve fully closed notification value).FUEL INJECTION SYSTEM Fault code No.12. Relay is not turned ON even if the crank signal is input while the start switch is turned ON. the fault code number might not appear on the meter. When the start switch is turned ON while an error is detected with the fault code of No. 8-33 .) After 20 minutes left idling. 30. you may not be able to start or drive the vehicle. Engine trouble warning light flashes when the start switch is turned ON. Faulty ECU memory. 41 or 50. Non-registered data has been received from the meter. (When this malfunction is detected in the ECU. Item ECU internal malfunction (output signal error) ECU internal malfunction (output signal error) ECU internal malfunction (output signal error) ECU internal malfunction (input signal error) Symptom Able / unable to start Able* Able / unable to drive Able* Er-1 No signals are received from the ECU. the ECU automatically stops the engine. 19.

G To increase the selected diagnostic code number. Perform ECU reinstatement action. then check the fault code number is not displayed. Identify the system with the malfunction. 5. repeat steps (1) to (4) until all fault code number is not displayed. Refer to “TROUBLESHOOTING DETAILS” on page 8-41. Simultaneously press and hold the “SELECT1” “1”and “RESET” “2” buttons. Press the “RESET” button for 1 second or longer to automatically decrease the diagnostic code numbers. press the “RESET” button. YES Check and repair. repair or replace it. Turn the main switch to “OFF” and set the engine stop switch to “ON”. NO Check and repair. NOTE: 3. 4. turn the main switch to “ON”. Refer to “Sensor operation table”.62)”. The engine operation is not normal but the engine trouble warning light does not come on. After selecting “dIAG”. Check the fault code number displayed on the meter. The malfunction history must be erased in the diagnostic mode. check and repair the engine inner parts. 7. Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the “SELECT1” and “RESET” buttons. Fault code No. Refer to “Self-Diagnostic Function table”. Identify the probable cause of malfunction. c. Refer to “Sensor operation table (Diagnostic code No. b.FUEL INJECTION SYSTEM EAS27400 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on. Fault code No. Refer to “TROUBLESHOOTING DETAILS” on page 8-41. and continue to press the buttons for 8 seconds or more. 6. Disconnect the wire harness coupler from the fuel pump. simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selection. Check: G Fault code number MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM If malfunction the sensors or actuators. G “dIAG” appears on the clock LCD. 2 1 2. Turn the main switch to “OFF” and back to “ON”. NOTE: displays on the meter disappear except the clock and tripmeter displays. Refer to “Reinstatement method” of table in “TROUBLESHOOTING DETAILS”. The Malfunction history is stored even if the main switch is turned OFF. If not malfunction the sensors and actuators. 1. 2. 3. 1. 4. Set the engine stop switch to “OFF”. Refer to “Diagnostic monitoring code table”. 5. Checking and repair the probable case of malfunction. Monitor the operation of the sensors and actuators in the diagnostic mode. Press the “SELECT” button for 1 second or longer to automatically increase the diagnostic code num- 8-34 . 01: Throttle position sensor (throttle angle) 30: Ignition coil #1 36: Injector #1 48: AI solenoid The diagnostic code number appears on the clock LCD (01–70). G To decrease the selected diagnostic code number. Press the “SELECT1” button to select the CO adjustment mode “CO” or the diagnostic mode “dIAG”. press the “SELECT” button. EAS27441 a. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL DIAGNOSTIC MODE Setting the diagnostic mode 1. NOTE: G All If other fault code displayed. Check the operation of following sensors and actuators in the Diagnostic mode. Refer to “Sensor operation table”.

G Sensor operation The data representing the operating conditions of the sensor appears on the trip LCD. 8.FUEL INJECTION SYSTEM bers. and then set it to “ON” again. 8-35 . NOTE: If the engine stop switch is set to “ON”. Verify the operation of the sensor or actuator. set it to “OFF”. 9. G Actuator operation Set the engine stop switch to “ON” to operate the actuator. Turn the main switch to “OFF” to cancel the diagnostic mode.

Open circuit is detected in the input line from the sidestand switch to the ECU. 03 14 Intake air pressure sensor hose is clogged. G Malfunction in ECU. G Improperly installed sensor. EXUP servo motor circuit open or short circuit. Defective lean angle sensor. Malfunction in ECU. G Malfunction in ignition coil. G Malfunction in ECU. 01 17 Open circuit in wire harness. 30 41 Lean angle sensor-open or short circuit detected. Symptom G Probable cause of malfunction Diagnostic code No. Stuck throttle position sensor detected. Intake air pressure sensor-pipe system malfunction (clogged hose). G Improperly installed lean angle sensor. Open or short circuit in wire harness. Defective throttle position sensor. G Malfunction in ECU.FUEL INJECTION SYSTEM Diagnostic code table Fault code No. G Malfunction in ECU. G Malfunction in ECU. 03 G Malfunction in ECU. G G G — 13 Intake air pressure sensor-open or short circuit detected. G Improperly installed intake air temperature sensor. Throttle position sensor-open or short circuit detected. Defective lean angle sensor. Coolant temperature sensor-open or short circuit detected. G EXUP servo motor lockup (valve or motor) G G 53 19 Open or short circuit in wire harness. G G 08 33 Malfunction detected in the primary wire of the ignition coil. Defective intake temperature sensor. Defective coolant temperature sensor. G Malfunction in ECU. G Malfunction in ECU. G G 06 22 Intake air temperature sensor-open or short circuit detected. Open or short circuit in wire harness. G Malfunction in ECU. Open or short circuit in wire harness. G G G G G 15 01 16 Stuck throttle position sensor. G Malfunction in pickup rotor. Defective intake air pressure sensor. G 53 18 Open circuit in wire harness. No normal signal is received from the lean angle sensor. G Malfunction in a component of ignition cut-off circuit system. G Defective crankshaft position sensor. G ECU is defective. Open or short circuit in wire harness. EXUP servo motor is stuck. 12 No normal signals are received from the crankshaft position sensor. The vehicle has overturned. Open or short circuit in wire harness. Defective EXUP servo motor. G 20 21 Open or short circuit in wire harness. G G G 05 30 Latch up detected. Open or short circuit in wire harness. G Malfunction in ECU. G 08 8-36 .

the fault code number might not appear on the meter. G Malfunction in ECU. 09 G 44 60 46 G — G 50 — 70 G — G G Er-1 Open or short circuit in communication line. G G G Er-3 Open or short circuit in communication line. Error is detected while reading or writing on EEPROM. Power supply to the FI system relay is not normal. Malfunction in ECU. Er-4 Non-registered data has been received from the meter. Open or short circuit in wiring harness.FUEL INJECTION SYSTEM Fault code No. — Malfunction in meter unit. Symptom G Probable cause of malfunction Diagnostic code No. No normal signals are received from the speed sensor. G Defective neutral switch. Faulty ECU memory. Open or short circuit in communication line. Malfunction in ECU. G Malfunction in ECU. — G Malfunction in meter unit. G G G 21 43 Open circuit in wire harness. Data from the ECU cannot be received correctly.) After 20 minutes left idling. G Malfunction in ECU. G 8-37 . G 07 Open circuit in wire harness. G Malfunction in ECU. G Sensor operation table Diagnos tic monitori ng code No. G ECU is defective. Malfunction in ECU. — Malfunction in meter unit. G Malfunction in vehicle speed sensor detected unit. Supply power to the fuel injector and fuel pump is not normal. 01 Item Meter display Checking method Throttle angle G Fully closed position Fully opened position 15–19 95–100 Check with throttle fully closed. G Defective relay unit (fuel pump). the ECU automatically stops the engine. No signals are received from the ECU within the specified duration.) Left idle control No signals are received from the ECU. Check with throttle fully open. G Malfunction in ECU. G Er-2 Open or short circuit in communication line. (CO concentration adjustment valve cannot be correctly written to or read from internal memory) Malfunction in charging system. Defective speed sensor. — Malfunction in meter unit. 42 Open or short circuit in neutral switch. (When this malfunction is detected in the ECU. (The program and data are not properly written on or read from the internal memory.

and then push the start switch. (If the display value changes.4 V 3.FUEL INJECTION SYSTEM Diagnos tic monitori ng code No. Set “ ” the engine stop switch. the performance is OK. Remove the lean angle sensor and incline it more than 65 degrees. 03 Item Meter display Checking method Pressure difference (atmospheric pressure-intake air pressure) Displays the intake air pressure.) 05 Intake air temperature 06 Coolant temperature Displays the coolant temperature. Compare with the actually measured battery voltage. Check that the number changes (integrating) when the rear wheels are rotated. perform recharging. (with the transmission in gear) Shift the transmission.4–1. Compare the actually measured intake air temperature with the meter display value. (*1) Compare the actually measured coolant temperature with the meter display value. (If the battery voltage is lower.4 V Approximately 12. 0–999 07 Vehicle speed pulse 08 Lean angle sensor G G Upright Overturned 0.7–4.) Set ON/OFF the sidestand switch. ON OFF — 00 04 (Throttle valve fully open notification value is detected.0 V 09 Fuel system voltage (battery voltage) 20 Sidestand switch G G Stand retracted Stand extended ON OFF 21 Neutral switch G G Neutral In gear 60 EEPROM fault code display G G No fault History exists 8-38 .) Displays the intake air temperature.

Actuates the air inducton system solenoid for five times every second. the display alternates every two seconds to show all the detected code numbers. turn ON the engine stop switch. Item Actuation Checking method 30 Ignition coil Actuates the ignition coil for five times every second. Light OFF: Air induction system solenoid “OFF”) Check the spark five times. 36 Injector Check the operating sound of the injector five times. Illuminates the engine trouble warning light.) 62 Malfunction history code erasure G G No history History exists 00 00–20 (Memory numbers of the fault detection) — To erase the history. 63 Repeated display of trouble code G G No malfunction code Malfunction code exists 0 Trouble code 24 00–255 — 70 Control number — *1 If it is not possible to check the intake temperature. Actuates the injector for five times every second. (Light OFF: Air induction system solenoid “ON”. Illuminates the engine trouble warning light. 61 Item Meter display Checking method Malfunction history code display G G — 00 12–70 (Fault detection code) G No history History exists (If code numbers more than one are detected. When all code numbers are shown. Actuator operation table Diagnos tic monitori ng code No.FUEL INJECTION SYSTEM Diagnos tic monitori ng code No. G Connect an ignition checker. 8-39 . Illuminates the engine trouble warning light. use the ambient temperature as reference (use the compared values for reference). the display repeats the same process. 48 Air induction system solenoid Check the operating sound of the solenoid five times.

Illuminates the engine trouble warning light. 8-40 . (The engine trouble warning light is OFF when the relay is ON. Actuates the radiator fan motor relay for five times every second. OFF three seconds) Illuminates the engine trouble warning light five times. Actuates the headlight relay for five times every five-second. OFF three seconds) Illuminates the engine trouble warning light. (ON two seconds.FUEL INJECTION SYSTEM Diagnos tic monitori ng code No. Illuminates the engine trouble warning light. Turn the servo motor once in the open direction and then in the close direction. Actuates the fuel injection system relay for five times every second. Item Actuation Checking method 49 Intake solenoid Actuates the intake solenoid for five times every second. 52 Headlight relay Check the operating sound of the headlight relay five times. and the engine trouble warning light is ON when the relay is OFF). Check the operating sound of the solenoid five times. 51 Radiator fan motor relay Check the operating sound of the relay five times. 53 EXUP servo motor Check the operating sound of the EXUP motor. (ON two seconds. Illuminates the engine trouble warning light. 50 Fuel injection system relay Check the operating sound of the relay five times.

Fault code No.: Fault code number displayed on the meter when the engine failed to work normally. (Green/White–Green/White) (Black/Blue–Black/Blue) G G 4 Defective crankshaft position sensor. G If there is a malfunction. Repair or replace if there is an open or short circuit. 3 Open or short circuit in wire harness. — Check or maintenance job Check the installed area for looseness or pinching. Carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the order. When the check and maintenance of malfunctioned part is completed. Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on page 8-75. Refer to “DIAGNOSTIC MODE” on page 8-34. Check the coupler for any pins that may have pulled out. Replace if defective. G Between the crankshaft position sensor coupler and ECU coupler. G Check the locking condition of the coupler. 12 Symptom — No normal signals are received from the crankshaft position sensor. repair it and connect it securely. G Diagnostic monitoring code No. Order Item/components and probable cause 1 2 Installed condition of crankshaft position sensor Connected state of connector Crankshaft position sensor coupler G Main wire harness ECU coupler G Reinstatement method Cranking the engine. restore the meter display according to the “Reinstatement method”. Refer to “DIAGNOSTIC MODE” on page 8-34. 8-41 .FUEL INJECTION SYSTEM EAS27480 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Fault code No. Diagnostic monitoring code No.: Code number to be used when the diagnostic monitoring mode is operated.

G Check the locking condition of the coupler. G If there is a malfunction. idle. (Code No. Intake air pressure sensor Check or maintenance job G Diagnostic monitoring code No. Check the coupler for any pins that may have pulled out. Intake air pressure sensor Check or maintenance job Check the coupler for any pins that may have pulled out. Connected state of connector Intake air pressure sensor coupler G Main wire harness ECU coupler G Check the intake air pressure sen. G Check and repair the connection.FUEL INJECTION SYSTEM Fault code No. repair it and connect it securely. Fault code No. G Between intake air pressure sensor coupler and ECU coupler (Black/Blue–Black/Blue) (Pink/White–Pink/White) (Blue–Blue) 3 Defective intake air pressure sensor Execute the diagnostic monitoring mode. Order Item/components and probable cause 1 Connected state of connector Intake air pressure sensor coupler G Main wire harness ECU coupler G Reinstatement method Turning the main switch ON. Repair or replace if there is an open or short circuit.03) G Replace if defective.03) G Replace if defective. (Code No.Starting the engine and sor hose condition. G Check the locking condition of the coupler. G G Diagnostic monitoring code No. Order Item/components and probable cause 1 Intake air pressure sensor hose clogged. 8-42 . G Refer to “CHECKING THE INTAKE AIR PRESSURE SENSOR” on page 8-80. operating it at G Repair or replace the sensor hose. 2 Open or short circuit in wire harness. G 4 Defective intake air pressure sensor Execute the diagnostic monitoring mode. Reinstatement method 2 3 Intake air pressure sensor malfunction at intermediate electrical potential. 14 Symptom 03 Intake air pressure sensor-hose system malfunction (clogged hose). G If there is a malfunction. G Refer to “CHECKING THE INTAKE AIR PRESSURE SENSOR” on page 8-80. repair it and connect it securely. 13 Symptom 03 Intake air pressure sensor-open or short circuit detected.

G Check the locking condition of the coupler. 15 Symptom 01 Throttle position sensor-open or short circuit detected. Order Item/components and probable cause 1 Installed condition of throttle position sensor. (Code No.FUEL INJECTION SYSTEM Fault code No. Output voltage 5V 0V 0V (Black/Blue–Yellow) Open circuit item Ground wire open circuit Output wire open circuit Power supply wire open circuit 5 Defective throttle position sensor. repair it and connect it securely.Turning the main switch ON. G If there is a malfunction. G G 2 Connected state of connector Throttle position sensor coupler G Main wire harness ECU coupler G 3 Open or short circuit in wire harness and/ or sub lead. G Check that is installed in the specified position. Reinstatement method Check the installed area for loose. G Check for open circuit and replace the throttle position sensor. G Between throttle position sensor coupler and ECU coupler (Black/Blue–Black/Blue) (Yellow–Yellow) (Blue–Blue) 4 Throttle position sensor lead wire open circuit output voltage check. Throttle position sensor Check or maintenance job G Diagnostic monitoring code No. Refer to “CHECKING THE THROTTLE POSITION SENSOR” on page 8-79. G Execute the diagnostic monitoring mode. Check the coupler for any pins that may have pulled out. Repair or replace if there is an open or short circuit. ness or pinching. 8-43 .01) G Replace if defective.

G Refer to “CHECKING THE THROTTLE POSITION SENSOR” on page 8-79. (Code No. (Code No. Order Item/components and probable cause 1 Connected state of connector. 2 Defective throttle position sensor. G Check that is installed in the specified position. 8-44 . G Diagnostic monitoring code No. G If there is a malfunction. Order Item/components and probable cause 1 Installed condition of throttle position sensor. Fault code No. 16 Symptom 01 Stuck throttle position sensor detected. repair it and connect it securely. Repair or replace if there is an open or short circuit.01) G Replace if defective. EXUP servo motor coupler G Wire harness ECU coupler Reinstatement method Turn the main switch to “ON”. 17 Symptom 53 EXUP servo motor circuit open or short circuit EXUP servo motor Check or maintenance job Check the coupler for any pins that may have pulled out. And then racing it. G 2 Open or short circuit in wire harness. G Check the locking condition of the coupler. operating it at idle.53) G Replace if defective.FUEL INJECTION SYSTEM Fault code No. Execute the diagnostic monitoring mode. Reinstatement method Reinstated by starting the engine. Throttle position sensor Check or maintenance job Check the installed area for looseness or pinching. G Between EXUP servo motor coupler and ECU coupler G (Black/Blue–Black/Blue) (White/Red–White/Red) (Blue–Blue) 3 Defective EXUP servo motor G Execute the diagnostic monitoring mode. G Diagnostic monitoring code No.

(Code No. 8-45 . G (Blue/Yellow–Blue/Yellow) Between ECU and main switch coupler. G G Diagnostic monitoring code No. Order Item/components and probable cause 1 Connected state of connector Main wire harness ECU coupler Reinstatement method If the transmission is in gear.20) G Check the coupler for any pins that may have pulled out. 19 Symptom 20 Replace if defective.FUEL INJECTION SYSTEM Fault code No. Repair or replace if there is an open or short circuit. EXUP servo motor coupler G Wire harness ECU coupler G Reinstatement method Turn the main switch to “ON”. G G Diagnostic monitoring code No. 18 Symptom 53 EXUP servo motor is stuck. Sidestand switch Check or maintenance job Execute the diagnostic monitoring mode. Fault code No. Repair or replace if there is an open or short circuit. G If there is a malfunction. If the transmission is in neutral. G Check the locking condition of the coupler.53) G Replace if defective. repair it and connect it securely. Order Item/components and probable cause 1 Connected state of connector. Replace if defective. G G 4 Defective EXUP valve. Open circuit is detected in the input line from the sidestand switch to the ECU. G 2 Open or short circuit in wire harness. (Blue/Black–Blue/Black) 3 Defective sidestand switch. G If there is a malfunction. G Refer to “CHECKING THE SWITCHES” on page 8-63. reconnecting the wiring. G Between EXUP servo motor coupler and ECU coupler (Black/Red–Black/Red) (Black/Green–Black/Green) 3 Defective EXUP servo motor Execute the diagnostic monitoring mode. 2 Open or short circuit in wire harness. G Between relay unit and main switch coupler. repair it and connect it securely. G Check the locking condition of the coupler. retracting the sidestand. EXUP servo motor Check or maintenance job Check the coupler for any pins that may have pulled out. pully and cable. (Code No.

Check the installed area for looseness or pinching.FUEL INJECTION SYSTEM Fault code No. Repair or replace if there is an open or short circuit. Order Item/components and probable cause 1 2 Installed condition of coolant temperature sensor. Execute the diagnostic monitoring mode. (Code No. repair it and connect it securely.06) G Replace if defective. G (Black–Black/Blue) (Black–Green/Red) 4 Defective coolant temperature sensor. Connected state of connector Coolant temperature sensor coupler G Main wire harness ECU coupler G Sub-wire harness coupler Check the coupler for any pins that may have pulled out. Coolant temperature sensor Check or maintenance job G Diagnostic monitoring code No. 21 Symptom 06 Coolant temperature sensor-open or short circuit detected. 8-46 . G 3 Open or short circuit in wire harness and/ or sub lead. G Check the locking condition of the coupler. G Reinstatement method Turning the main switch ON. G Between coolant temperature sensor coupler and ECU coupler. G Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR” on page 8-78. G If there is a malfunction.

G (Black/Blue–Black/Blue) (Brown/White–Brown/White) 4 Defective intake air temperature sensor. Check the installed area for looseness or pinching.08) G Replace if defective. repair it and connect it securely. Order Item/components and probable cause 1 2 Installed condition of intake air temperature sensor. 22 Symptom 05 Intake air temperature sensor-open or short circuit detected. G 4 Defective lean angle sensor. Raise the vehicle upright. Repair or replace if there is an open or short circuit. G If there is a malfunction. Intake air temperature sensor Check or maintenance job G Diagnostic monitoring code No. 30 Symptom 08 Latch up detected. G 8-47 . G 3 Open or short circuit in wire harness and/ or sub lead.05) G Replace if defective. Installed condition of the lean angle sensor G Reinstatement method Turning the main switch ON (however. Execute the diagnostic monitoring mode. repair it and connect it securely. Lean angle sensor Check or maintenance job G G Diagnostic monitoring code No.FUEL INJECTION SYSTEM Fault code No. G Execute the diagnostic monitoring mode. Check the installed area for looseness or pinching. Fault code No. (Code No. Connected state of connector Lean angle sensor coupler G Main wire harness ECU coupler Check the coupler for any pins that may have pulled out. G Reinstatement method Turning the main switch ON. G Check the locking condition of the coupler. G Check the locking condition of the coupler. Refer to “CHECKING THE INTAKE AIR TEMPERATURE SENSOR” on page 8-80. No normal signal is received from the lean angle sensor. (Code No. Connected state of connector Intake air temperature sensor coupler G Main wire harness ECU coupler Check the coupler for any pins that may have pulled out. G If there is a malfunction. G Between intake air temperature sensor coupler and ECU coupler. Order Item/components and probable cause 1 2 3 The vehicle has overturned. the engine cannot be restarted unless the main switch is first turned OFF).

2 Open or short circuit in wire harness. G (Black/Blue–Black/Blue) (Yellow/Green–Yellow/Green) (Blue–Blue) 3 Defective lean angle sensor G Execute the diagnostic monitoring mode. (Orange–Orange) 3 Defective ignition coil G Execute the diagnostic monitoring mode. Ignition coil Check or maintenance job Check the coupler for any pins that may have pulled out. Repair or replace if there is an open or short circuit. Repair or replace if there is an open or short circuit. G G Diagnostic monitoring code No. Order Item/components and probable cause 1 Connected state of connector Lean angle sensor coupler G Main wire harness ECU coupler G Reinstatement method Turning the main switch ON. repair it and connect it securely. G If there is a malfunction. G If there is a malfunction.FUEL INJECTION SYSTEM Fault code No. Lean angle sensor Check or maintenance job Check the coupler for any pins that may have pulled out. G Between switch coupler and ECU coupler.08) G Replace if defective. repair it and connect it securely. 2 Open or short circuit in wire harness or sub lead. G Diagnostic monitoring code No. G Check the locking condition of the coupler. (Code No. 41 Symptom 08 Lean angle sensor-open or short circuit detected. G Replace if defective. Refer to “CHECKING THE IGNITION COIL” on page 8-74. 33 Symptom 30 Malfunction detected in the primary wire of the ignition coil. (Code No. Refer to “CHECKING THE LEAN ANGLE SENSOR” on page 8-75. Fault code No. G Check the locking condition of the coupler. G Between ignition coil coupler and ECU coupler/main wire harness.30) G Test the primary and secondary coils for continuity. Order Item/components and probable cause 1 Connected state of connector Ignition coil primary side coupler (Orange) G Main wire harness ECU coupler G Reinstatement method Starting the engine and operating it at idle. 8-48 .

(Blue–Blue) (White–White) (Black/Blue–Black/Blue) A-4 Defective speed sensor. (Code No. Repair or replace if there is an open or short circuit.FUEL INJECTION SYSTEM Fault code No. G Check the locking condition of the coupler. Check the coupler for any pins that may have pulled out. Open or short circuit is detected in the neutral switch. Execute the diagnostic monitoring mode. 42 Symptom A B 07 21 A. Check the installed area for looseness or pinching. G If there is a malfunction. B.07) G Replace if defective. Speed sensor coupler G Wire harness ECU coupler G Reinstatement method Starting the engine. G Between sensor coupler and ECU coupler. G G A-3 Open or short circuit in speed sensor lead. Speed sensor Neutral switch Check or maintenance job G Diagnostic monitoring code No. No normal signals are received from the speed sensor. repair it and connect it securely. and inputting the vehicle speed signals by operating the motorcycle at a low speed of 20–30 km/h. G Refer to “CHECKING THE SPEED SENSOR” on page 8-77. Order Item/components and probable cause A-1 A-2 Installed condition of speed sensor Connected state of connector. 8-49 .

21) G Replace if defective. 8-50 . Open or short circuit is detected in the neutral switch. No normal signals are received from the speed sensor. Refer to “TRANSMISSION” on page 5-64. G Check the coupler for any pins that may have pulled out. 42 Symptom A B 07 21 A. Speed sensor Neutral switch Check or maintenance job G Diagnostic monitoring code No. G Between relay unit coupler and ECU coupler G (Black/Yellow–Black/Yellow) G Between neutral switch and relay unit coupler (Sky blue–Sky blue) B-4 Defective neutral switch Execute the diagnostic monitoring mode. G Check the locking condition of the coupler. Neutral switch coupler G Wire harness ECU coupler Reinstatement method Turn the main switch to “ON”. Order Item/components and probable cause B-1 B-2 Installed condition of neutral switch Connected state of connector. Check the installed area for looseness or pinching. B. Repair or replace if there is an open or short circuit.FUEL INJECTION SYSTEM Fault code No. G B-3 Open or short circuit in speed sensor lead. G If there is a malfunction. G Refer to “CHECKING THE SWITCHES” on page 8-63. repair it and connect it securely. (Code No. B-5 Defective shift drum (neutral detection location) G Replace if defective.

60) 2. 09) G Charge or replace if defective. Order Item/components and probable cause 1 Malfunction in ECU 8-51 . 43 Symptom 09 Supply power to the fuel injector and fuel pump is not normal. Execute the diagnostic monitoring mode. and set the abnormal exhaust gas level. Order Item/components and probable cause 1 Connected state of connector Relay unit coupler G Fuel pump coupler G Fuel injector coupler G ECU coupler G Reinstatement method Starting the engine and operating it at idle. Repair or replace if there is an open or short circuit.) Diagnostic monitoring code No. G Between relay unit and ECU coupler G (Red/Blue–Red/Blue) G G Between relay unit and fuse (EFI) Between fuse (EFI) and battery (Brown/Yellow–Brown/Yellow) (Brown/Yellow–Brown/Yellow) 3 Faulty battery voltage Execute the diagnostic monitoring mode.FUEL INJECTION SYSTEM Fault code No. 2 Open or short circuit in the wire harness. (Code No. Reinstatement method Turn the main switch to “ON”. G When defect cannot be repaired. (When displayed again. replace the ECU. EEPROM improper cylinder indication Check or maintenance job 1. Adjust the CO exhaust gas level. Fuel system voltage Check or maintenance job Check the coupler for any pins that may have pulled out. G Diagnostic monitoring code No. 44 Symptom 60 Error is detected while reading or writing on EEPROM (CO adjustment valve). Set until “0” is shown on the display. G Fault code No. repair it and connect it securely. (Code No. readjust the exhaust gas. G Check the locking condition of the coupler. G If there is a malfunction.

repair it and connect it securely. Repair or replace if there is an open or short circuit. 4 Open or short circuit in the wire harness. Order Item/components and probable cause 1 Connected state of connector Wire harness ECU coupler Reinstatement method Starting the engine and operating it at idle. — Check or maintenance job G Diagnostic monitoring code No. G Check the locking condition of the coupler. 50 Symptom — Faulty ECU memory. (When this malfunction is detected in the ECU. G Check the coupler for any pins that may have pulled out.) — Check or maintenance job G Diagnostic monitoring code No. G If there is a malfunction. 8-52 . G Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-68. the fault code number might not appear on the meter. 2 Faulty battery. (Red–Red) G Between main switch and fuse (ignition) Between fuse (ignition) and ECU (Brown–Brown) G (Red/White–Red/White) Fault code No. Replace or charge the battery.FUEL INJECTION SYSTEM Fault code No. Refer to “CHARGING SYSTEM” on page 8-11. Order Item/components and probable cause 1 Malfunction in ECU Reinstatement method Turning the main switch ON Replace the ECU. 46 Symptom — Power supply to the FI system relay is not normal. 3 Malfunction of the rectifier/regulator G G Replace if defective. G Between battery and main switch.

G Between meter coupler and ECU coupler G (Yellow/Blue–Yellow/Blue) 3 4 Malfunction in meter unit Malfunction in ECU Er-2 Symptom — G G Replace the meter unit. G Check the coupler for any pins that may have pulled out. G If there is a malfunction. repair it and connect it securely. Er-1 Symptom — No signals are received from the ECU. G If there is a malfunction. G Check the locking condition of the coupler. repair it and connect it securely. G Diagnostic monitoring code No. Replace the ECU. G Between meter coupler and ECU coupler G (Yellow/Blue–Yellow/Blue) 3 4 Malfunction in meter unit Malfunction in ECU G G Replace the meter unit. Fault code No. — Check or maintenance job Check the coupler for any pins that may have pulled out. G Check the locking condition of the coupler. Replace the ECU. G 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit. 8-53 . — Check or maintenance job G Diagnostic monitoring code No. 2 Open or short circuit in wire harness lead Repair or replace if there is an open or short circuit.FUEL INJECTION SYSTEM Fault code No. Order Item/components and probable cause 1 Connected state of connector Main wire harness ECU coupler Reinstatement method Reinstated if normal signal is received from the ECU when the main switch is turn to ON. Order Item/components and probable cause 1 Connected state of connector Main wire harness ECU coupler Reinstatement method Reinstated if normal signal is received from the ECU when the main switch is turn to ON. No signals are received from the ECU within the specified duration.

Replace the ECU. — Check or maintenance job Check the coupler for any pins that may have pulled out. 8-54 . G Check the locking condition of the coupler. Order Item/components and probable cause 1 Connected state of connector Main wire harness ECU coupler Reinstatement method Reinstated if normal signal is received from the ECU when the main switch is turn to ON. G Between meter coupler and ECU coupler G (Yellow/Blue–Yellow/Blue) 3 4 Malfunction in meter unit Malfunction in ECU Er-4 Symptom — G G Replace the meter unit. Fault code No. Non-registered data has been received from the meter. 2 Open or short circuit in wire harness lead. Order Item/components and probable cause 1 Connected state of connector Main wire harness ECU coupler Reinstatement method Reinstated if normal signal is received from the ECU when the main switch is turn to ON. — Check or maintenance job G Diagnostic monitoring code No. Replace the ECU. G 2 Open or short circuit in wire harness lead. repair it and connect it securely. G Between sensor coupler and ECU coupler G (Yellow/Blue–Yellow/Blue) 3 4 Malfunction in meter unit Malfunction in ECU G G Replace the meter unit. G If there is a malfunction. G Check the locking condition of the coupler.FUEL INJECTION SYSTEM Fault code No. Repair or replace if there is an open or short circuit. Repair or replace if there is an open or short circuit. Er-3 Symptom — Data from the ECU cannot be received correctly. repair it and connect it securely. G If there is a malfunction. G Diagnostic monitoring code No. G Check the coupler for any pins that may have pulled out.

FUEL PUMP SYSTEM EAS27580 FUEL PUMP SYSTEM EAS27590 CIRCUIT DIAGRAM 8-55 .

Battery 5. Main fuse 8.FUEL PUMP SYSTEM 3. ECU 56. Ignition fuse 58. Right handlebar switch 9. Fuel pump 16. Relay unit 15. EFI fuse 8-56 . Main switch 4. Engine stop switch 11.

Refer to “CIRCUIT DIAGRAM” on page 8-55. 8-57 . Check the engine stop switch. NG→ GClean GRecharge NG→ Replace the fuse(s). Refer to “CHECKING THE SWITCHES” on page 8-63. the battery terminals. or replace the battery. NOTE: Before troubleshooting. Check the main switch. OK↓ 2. OK↓ 3. Side cover (left/right) 3. ignition fuse. Check the fuse (Main fuse. Check the fuel pump system wire harness connections. NG→ Replace relay unit (fuel pump relay) NG→ Replace the right handlebar switch. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-68. Check fuel pressure Refer to “CHECKING THE PRESSURE REGULATOR” on page 7-6. OK↓ 7.FUEL PUMP SYSTEM EAS27600 TROUBLE SHOOTING The fuel pump fails to operate. OK↓ Replace the ECU. Seat 2. NG→ Replace the fuel pump. Check the relay unit (fuel pump relay). NG→ Replace the main switch. Check the battery. OK↓ 6. NG→ Properly connect or repair the fuel pump system’s wiring. Refer to “CHECKING THE SWITCHES” on page 8-63. EFI fuse) Refer to “CHECKING THE FUSES” on page 8-67. OK↓ 5. OK↓ 4. Refer to “CHECKING THE SWITCHES” on page 8-63. Fuel tank 1. remove the following part(s): 1.

FUEL PUMP SYSTEM 8-58 .

ELECTRICAL COMPONENTS EAS27971 ELECTRICAL COMPONENTS EAS32D1011 1 2 5 3 4 6 7 13 8 11 12 9 10 8-59 .

Throttle position sensor 9. Rear brake switch 12. Fan motor 13. Neutral switch 11.ELECTRICAL COMPONENTS 1. Battery 3. ECU 6. Rectifier/regulator 8-60 . Main fuse 4. Main switch 2. Sidestand switch 10. Intake solenoid 8. Starter relay 5. Lean angle sensor 7.

ELECTRICAL COMPONENTS 2 3 4 5 1 6 7 15 8 9 13 10 14 11 12 8-61 .

ELECTRICAL COMPONENTS 1. Starter motor 4. Speed sensor 11. EXUP servo motor 12. Radiator fan motor relay 5. Air cut-off valve 8-62 . Turn signal relay 6. Headlight relay 8. Relay assembly 7. Fuel pump 15. Horn 2. Intake air temperature sensor 9. Fuse box 3. Coolant temperature sensor 10. Ignition coil 14. Injector 13.

ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 1 7 2 8 3 9 4 10 5 11 6 8-63 .

Neutral switch 6. Turn signal switch 4. Sidestand switch 7. Horn switch 2.ELECTRICAL COMPONENTS 1. Engine stop switch 9. Start switch 10. Rear brake switch 8-64 . Front brake switch 11. Main switch 8. Dimmer switch 3. Clutch switch 5.

The terminal connections for switches (e.. taking care not to loosen or damage the leads. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “1”. 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. Pocket tester 90890-03112 Analog pocket tester YU-03112-C NOTE: G Before G When checking for continuity. switch back and forth between the switch positions a few times. The example illustration below shows that: There is continuity between red and brown blue/yellow and blue/black when the switch is set to “ON”.e. a closed circuit at the respective switch position). engine stop switch) are shown in an illustration similar to the one on below. main switch.ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. replace the switch. Always insert the probes from the opposite end of the coupler. b a 8-65 . set the pocket tester to “0” and to the “Ω × 1” range. NOTE: “ ” indicates a continuity of electricity between switch terminals (i. If the continuity reading is incorrect. checking for continuity. check the wiring connections and if necessary..g.

Damage/wear → Repair or replace the bulb. b. If either of the readings indicate no continuity. Connect the positive tester probe to terminal “1” and the negative tester probe to terminal “3”. keep flammable products and your hands 8-66 . G Bulbs “a” and “b” are used for the headlights and usually use a bulb holder that must be detached before removing the bulb. 1. thoroughly it with a cloth moistened with alcohol or lacquer thinner. No continuity → Repair or replace the bulb.ELECTRICAL COMPONENTS EAS27990 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear. replace the bulb. and also for continuity between the terminals. G Bulbs “c” is used for turn signal and can be removed from the socket by pushing and turning the bulb counterclockwise. The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise. proper connections. otherwise the transparency of the glass. Pocket tester 90890-03112 Analog pocket tester YU-03112-C NOTE: G Be Before checking for continuity. bulb socket or both. otherwise it may be pulled out of the terminal in the coupler. 2. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. and check the continuity. bulb socket or both. Improperly connected → Properly connect. and the luminous flux will be adversely affected. G Avoid touching the glass part of the headlight bulb to keep it free from oil. Types of bulbs The bulbs used on this vehicle are shown in the illustration on the left. and check the continuity. c. Remove: G Bulb EWA13320 WARNING Since the headlight bulb gets extremely hot. Check: G Bulb (for continuity) (with the pocket tester) No continuity → Replace. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Checking the condition of the bulbs The following procedure applies to all of the bulbs. away from the bulb until it has cooled down. the life of the bulb. ECA14380 CAUTION: sure to hold the socket firmly when removing the bulb. set the pocket tester to “0” and to the “Ω × 1” range. If the headlight bulb gets soiled. Never pull the lead. Connect the positive tester probe to terminal “1” and the negative tester probe to terminal “2”.

Remove: G Side cover (left) G Air scoop (left) Refer to “GENERAL CHASSIS” on page 4-1. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. 1. Set the main switch to “OFF”. If the pocket tester indicates “∞”. NOTE: Set the pocket tester selector to “Ω × 1”. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL a. always set the main switch to “OFF” when checking or replacing a fuse. Check: G Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. note the following. Install a new fuse of the correct amperage rating. Replace: G Blown fuse MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM CAUTION: To avoid a short circuit. Connect the pocket tester probes to the respective leads of the bulb socket. c.ELECTRICAL COMPONENTS Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets. Set on the switches to verify if the electrical circuit is operational. Connect the pocket tester to the fuse and check the continuity. Check: G Main fuse “1” G Fuse box “2” 1 a. Check the bulb socket for continuity. Pocket tester 90890-03112 Analog pocket tester YU-03112-C NOTE: 2 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Check each bulb socket for continuity in the same manner as described in the bulb section. however. replace the fuse. 2. Install a good bulb into the bulb socket. If the fuse immediately blows again. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28000 CHECKING THE FUSES The following procedure applies to all of the fuses. d. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. ECA13680 3. If any of the readings indicate no continuity. c. b. b. 8-67 . 1. replace the bulb socket. check the electrical circuit.

and then positive battery lead “2”. G Eyes — Flush with water for 15 minutes and get immediate medical attention. the electrolyte level will drop considerably.g. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system. Remove: G Side cover (left) Refer to “GENERAL CHASSIS” on page 4-1. charging amperage and charging voltage for an MF battery are different from those of conventional batteries. EAS28030 CHECKING AND CHARGING THE BATTERY EWA13290 Since MF batteries are sealed.. lighted cigarettes). beaten egg or vegetable oil. take special care when charging the battery.ELECTRICAL COMPONENTS Fuses Main Headlight Signaling system Ignition EFI Radiator fan motor Backup Reserve Reserve Reserve Reserve EWA13310 Amperage rating 30A 15A 10A 7. Therefore. G Keep batteries away from fire. always follow these preventive measures: G Wear protective eye gear when handling or working near batteries. G Charging time. 1. cause the lighting and ignition systems to malfunction and could possibly cause a fire. G Charge batteries in a well-ventilated area.5A Q’ty 1 1 1 1 1 1 1 1 1 1 1 OUT OF REACH OF CHILDREN. Install: G Air scoop (left) G Side cover (left) Refer to “GENERAL CHASSIS” on page 4-1. sparks or open flames (e. Therefore. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL G Skin — Wash with water. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate.5A 7. G KEEP BATTERIES AND ELECTROLYTE CAUTION: First. INTERNAL G Drink large quantities of water or milk followed with milk of magnesia. 2. Therefore.5A 7.5A 7. it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. NOTE: G This LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. G Avoid ECA13660 CAUTION: WARNING Never use a fuse with an amperage rating other than that specified.5A 30A 15A 10A 7. is a sealed battery. Get immediate medical attention. the charge of the battery has to be checked by measuring the voltage at the battery terminals. disconnect the negative battery lead “1”. bodily contact with electrolyte as it can cause severe burns or permanent eye injury. The MF battery should be charged as explained in the charging method illustrations. 8-68 . Disconnect: G Battery band G Battery leads (from the battery terminals) ECA13640 WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. G DO NOT SMOKE when charging or handling batteries. welding equipment. If the battery is overcharged.

G If it is impossible to regulate the charging current on the battery charger.5 hours Charge of the battery = 20–30% (V) G The CAUTION: A (h) B A. Check the charge of the battery. G When charging a battery. G Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. Open-circuit voltage B. disconnect the negative battery lead from the battery terminal.) G To reduce the chance of sparks. Charging time remove the MF battery sealing caps. as shown in the charts and the following example. G Before removing the battery charger lead clips from the battery terminals. Open-circuit voltage B. Remove: G Battery 4. (If charging has to be done with the battery mounted on the vehicle. G If the battery becomes hot to the touch at any time during the charging process. do not plug in the battery charger until the battery charger leads are connected to the battery. ECA13670 charge state of an MF battery can be checked by measuring its open-circuit voltage (i. be sure to turn off the battery charger.e. be careful not to overcharge the battery. the voltage when the positive battery terminal is disconnected).8 V.ELECTRICAL COMPONENTS 1 C 2 A 3. Connect a pocket tester to the battery terminals. Charge of the battery C. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. b. be sure to remove it from the vehicle. Positive tester probe → positive battery terminal Negative tester probe → negative battery terminal NOTE: LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 5. Example Open-circuit voltage = 12. G No charging is necessary when the open-circuit voltage equals or exceeds 12.0 V Charging time = 6.. Charge: G Battery EWA13300 WARNING Do not quick charge a battery. G Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. disconnect the battery charger and let the bat- G Never 8-69 . Check: G Battery charge MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM B A. Temperature 20°C a.

the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed.Replace the battery. Measure the open-circuit voltage prior to charging. Temperature 20°C MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Charging method using a constant voltage charger a. 12. Charging the open-circuit voltage C. NOTE: Charging method using a variable-current (voltage) charger a. NOTE: If the current is lower than the standard charging current written on the battery. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 8-70 . Adjust the voltage so that the current is at the standard charging level. e. Under 12. Under 12. NOTE: Set the charging voltage at 16–17 V. d. Therefore. Does not reach the standard charging current Replace the battery. If there is any change in the amperage. c. Charge the battery until the battery’s charging voltage is 15 V. b. e. Set the time according to the charging time suitable for the open-circuit voltage. B A. 12.8 V or more --. c. A variable voltage charger is recommended. Reach the standard charging current Battery is good. b. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL A 12.ELECTRICAL COMPONENTS tery cool before reconnecting it. wait 30 minutes after charging is completed before measuring the open-circuit voltage. Hot batteries can explode! G As shown in the following illustration. Open-circuit voltage B. NOTE: Voltage should be measured 30 minutes after the machine is stopped.Replace the battery.Recharging is required. Refer to “Battery condition checking steps”. NOTE: Set the charging time at 20 hours (maximum).8 V or more --. 12. f.7 V or less --. Make sure that the current is higher than the standard charging current written on the battery. If the current is lower than the standard charging current written on the battery. Measure the open-circuit voltage prior to charging. charging will be insufficient. set the charging voltage adjust dial at 20–24 V and monitor the amperage for 3–5 minutes to check the battery. C d. g. If charging requires more than 5 hours. This type of battery charger cannot charge the MF battery.7 V or less --.0 V --. NOTE: Voltage should be measured 30 minutes after the machine is stopped.If the setting is lower. readjust the voltage to obtain the standard charging current.0 V --.Charging is complete. Connect a charger and AMP meter to the battery and start charging. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes.Charging is complete. Make sure that the current is higher than the standard charging current written on the battery. If too high. the battery will be over-charged. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes.Recharging is required. it is advisable to check the charging current after a lapse of 5 hours. Connect a charged and AMP meter to the battery and start charging.

EAS28040 Result Continuity (between “3” to “4”) Relay unit (starting circuit cut-off relay) 7 1. If the continuity reading is incorrect. 4. Connect the pocket tester (Ω × 1) and battery (12 V) to the relay terminal as shown. replace the relay. 4. 3. 2. Check the relay operation.Install: G Battery band 11. Install: G Battery 8. 7. Loose connection → Connect properly. 3. 2. 3. Starter relay 3 1. 2. Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1. Result Continuity (between “3” to “4”) Relay unit (fuel pump) 3 1 4 2 Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe 4 2 1 Result Continuity (between “3” to “4”) 1. Disconnect the relay from the wire harness. Lubricate: G Battery terminals Recommended lubricant Dielectric grease 10.Install: G Side cover (left) Refer to “GENERAL CHASSIS” on page 4-1. 4. 2. Connect: G Battery leads (to the battery terminals) 9.ELECTRICAL COMPONENTS 6. 6 3 4 1 5 2 Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe CHECKING THE RELAYS Check each switch for continuity with the pocket tester. Out of specification → Replace. Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe 8-71 . Check: G Battery terminals Dirt → Clean with a wire brush.

4. Connect the pocket tester (DC 20 V) to the turn signal relay terminal. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Tester positive probe Brown/White termnals “1” Negative tester probe Ground a. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 8-72 . c. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Tester positive probe Red/Blue “1” Negative tester probe Ground 1 b. 2. Check: G Turn signal relay input voltage Off specification →Repair wire harness connection failure from main switch to turn signal relay coupler Turn signal relay input voltage DC 12V MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. 3. Measure turn signal relay applied voltage.ELECTRICAL COMPONENTS Headlight relay 3 4 2 1 1 1. Turn the main switch to “ON”. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Result Continuity (between “3” to “4”) Checking the turn signal relay MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM d. Turn the main switch to “ON”. Measure turn signal relay applied voltage. Turn signal relay output voltage DC 12V MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal. c. Check: G Turn signal relay output voltage Out of specification → Replace the defective part (s). Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe b.

8-73 . Check: G Diode Out of specification → Replace. Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe Result Continuity (between “3” to “4”) EAS28050 CHECKING THE DIODE 1. a.ELECTRICAL COMPONENTS Radiator fan motor relay 3 4 2 1 Continuity Tester positive lead → Sky blue “1” Tester negative lead → Light green “2” No continuity Tester positive lead → Light green “2” Tester negative lead → Sky blue “1” Continuity Tester positive lead → Blue/ Green “3” Tester negative lead → Blue/Yellow “4” No continuity Tester positive lead → Blue/Yellow “4” Tester negative lead → Blue/ Green “3” Continuity Tester positive lead → Sky blue “1” Tester negative lead → Blue/Yellow “4” No continuity Tester positive lead → Blue/Yellow “4” Tester negative lead → Sky blue “1” Continuity Tester positive lead → Sky blue “1” Tester negative lead → Black/ Yellow “5” No continuity Tester positive lead → Black/ Yellow “5” Tester negative lead → Sky blue “1” Continuity Tester positive lead → Brown “6” Tester negative lead → Blue/ White “7” No continuity Tester positive lead → Blue/ White “7” Tester negative lead → Brown “6” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM 1. 2. Connect the pocket tester (Ω × 1) to the starting circuit cut-off relay coupler as shown. 3. Pocket tester 90890-03112 Analog pocket tester YU-03112-C NOTE: The pocket tester and the analog pocket tester readings are shown in the following table. Disconnect the starting circuit cut-off relay from the wire harness. b. 4.

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28090 7 6 3 4 1 5 2 CHECKING THE IGNITION COIL 1. Minimum ignition spark gap 6. Check the diode for continuity. b. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 2. e. Measure the ignition spark gap “a”. Disconnect the spark plug cap from the spark plug.24 in) NOTE: a. 1. Check the diode for no continuity. Check: G Ignition spark gap Out of specification → Perform the ignition system troubleshooting. Connect the ignition checker “1” as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Tester positive probe Red/Black termainal “1” Negative tester probe Orange terminal “2” If the ignition spark gap is within specification. starting with step *. d. Check: G Secondary coil resistance Out of specification → Replace. Connect the pocket tester (Ω × 1) to the ignition coil as shown. Spark plug cap 8-74 . Check: G Primary coil resistance Out of specification → Replace. Crank the engine by pushing the start switch “ ” and gradually increase the spark gap until a misfire occurs. c.0 mm (0. d. Turn the main switch to “ON” and engine stop switch to “ ”. Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487 c.61 Ω MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28930 CHECKING THE IGNITION SPARK GAP 1. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Ignition checker 2.19–1. Measure the primary coil resistance. the ignition system circuit is operating normally. Disconnect the ignition coil lead coupler from wire harness. b. Primary coil resistance 1. Refer to “TROUBLESHOOTING” on page 8-3.ELECTRICAL COMPONENTS c.

Connect the pocket tester (DC 20 V) to the lean angle sensor coupler as shown.4–1. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28130 c.) 2. Crankshaft position sensor resistance 248–372 Ω (R–W) a.4V MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM CHECKING THE CRANKSHAFT POSITION SENSOR 1. Connect the pocket tester (Ω × 1k) to the ignition coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C 8-75 .50 kΩ MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Red “1” Negative tester probe White “2” a. Disconnect: G Crankshaft position sensor coupler (from the wire harness) 2. Measure the crankshaft position sensor resistance. Connect the lean angle sensor coupler to the wireharness. Check: G Lean angle sensor out put voltage Out of specification → Replace. Check: G Crankshaft position sensor resistance Out of specification → Replace the crankshaft position sensor. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS32D1002 CHECKING THE LEAN ANGLE SENSOR 1. Disconnect the spark plug cap from the ignition coil. Connect the pocket tester (Ω × 100) to the crankshaft position sensor coupler as shown.50–11. Lean angle sensor out put voltage Less than 65° “a” 0. b. Remove: G Lean angle sensor (from the bracket. Measure the secondary coil resistance. b. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Red/Black “1” Negative tester probe Spark plug lead “2” 1 2 b.ELECTRICAL COMPONENTS Secondary coil resistance 8.7–4. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.4V More than 65° “b” 3.

LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28170 CHECKING THE STATOR COIL 1. b. d.252 Ω (W-W) a. Set the digital tachometer to the ignition coil of cylinder #1. Charging voltage 14 V at 5000 r/min MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.ELECTRICAL COMPONENTS Tester positive probe Blue “1” Negative tester probe Yellow/Green “2” a a Positive tester probe White “2” Negative tester probe White “3” ON ON 1 2 1 b c. Check: G Stator coil resistance Out of specification → Replace the stator coil. Check: G Charging voltage Out of specification → Replace the rectifier/ regulator. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28150 2 3 b. Connect the pocket tester (DC 20 V) to the rectifier/regulator coupler as shown. Measure the stator coil resistance. Stator coil resistance 0. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe White “1” Negative tester probe White “2” Positive tester probe White “1” Negative tester probe White “3” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM CHECKING THE RECTIFIER/REGULATOR 1.168–0. Disconnect: G Stator coil coupler (from the wire harness) 2. Connect the pocket tester (Ω × 1) to the stator coil coupler as shown. Incline the lean angle sensor. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Positive battery terminal “1” Negative tester probe Negative battery terminal “2” 8-76 . Measure the lean angle sensor out put voltage.

Check: G Speed sensor output voltage Out of specification → Replace. Horn resistance 1. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 8-77 . Disconnect the horn leads from the horn terminals. c. b. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Horn terminal “1” Negative tester probe Horn terminal “2” CHECKING THE SPEED SENSOR 1. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28180 a b CHECKING THE HORN 1.11 Ω at 20°C (68°F) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28240 a. Connect the pocket tester (Ω × 1) to the horn terminals. Check: G Horn resistance Out of specification → Replace. Turn the adjusting screw in direction “a” or “b” until the specified horn sound is obtained. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe White “1” Negative tester probe Black/Blue “2” 1 2 c.01–1. Check: G Horn sound Faulty sound → Adjust or replace. Measure the charging voltage. d. Connect a battery (12 V) to the horn.ELECTRICAL COMPONENTS  2. Start the engine and let it run at approximately 5000 r/min. Output voltage reading cycle 0 V–5 V–0 V–5 V–0 V MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown. b. Measure the horn resistance.

59 kΩ Resistance 80°C (176°F) 310–326 Ω a. 1. Set the main switch to “ON”. Remove: G Fuel pump (from the fuel pump tank) 3. EWA14130 WARNING the coolant temperature sensor with special care. Fuel sender resistance 0. replace it. Elevate the rear wheel and slowly turn it.32–2. Connect the pocket tester (kΩ × 1) to the fuel sender as shown. c. 2. Resistance 20°C (68°F) 2. Measure the resistance of the fuel sender. d. Check: G Fuel sender resistance Out of specification → Replace the fuel pump. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Black “1” Negative tester probe Black “2” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM G Handle 8-78 . G Never subject the coolant temperature sensor to strong shocks.88 kΩ a. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28260 CHECKING THE FUEL SENDER (FUEL PUMP) Drain the gasoline. Check: G Coolant temperature sensor resistance Out of specification → Replace.94–1. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe Green/White “1” Negative tester probe Black “2” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM CHECKING THE COOLANT TEMPERATURE SENSOR 1. With the front wheel slowly rotating. Remove: G Coolant temperature sensor Refer to “THERMOSTAT” on page 6-4. Connect the pocket tester (Ω × 100) to the coolant temperature sensor as shown. Measure the voltage (DC 5 V) of white and black/blue.ELECTRICAL COMPONENTS 1 2 1 2 b. Disconnect: G Fuel pump coupler (from the fuel pump) 2. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS32D1012 b. If the coolant temperature sensor is dropped. voltage alternates between 0 V and 5 V.

Place a thermometer in the coolant. Immerse the coolant temperature sensor in a container filled with coolant. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Tester positive lead → Yellow “1” Tester negative lead → Black/Blue “2” LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28250 CHECKING THE RADIATOR FAN MOTOR 1. Check: G Radiator fan motor Faulty/rough movement → Replace. e. Slowly heat the coolant. 1 c.ELECTRICAL COMPONENTS from the wire harness. Positive tester probe Blue “1” Negative tester probe Black “2” 1 2 2 b. Measure the radiator fan motor movement. Check: G Throttle position sensor MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Disconnect the radiator fan motor coupler 8-79 . Connect the battery (DC 12 V) as shown. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. Connect the pocket tester (DC 20 V) to the throttle position sensor as shown. NOTE: Make sure the coolant temperature sensor terminals do not get wet. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM 1 2 b. While slowly turning the throttle position sen- a. b. d. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1. c. and then let it cool to the specified temperature indicated in the table.

Positive battery lead Black/Green “1” Negative battery lead Black/Red “2” 2 1 b. Disconnect the EXUP servo motor coupler from the wire harness. Connect the battery leads to the EXUP servo motor coupler as shown. G Never subject the intake air temperature G Handle 8-80 .6–5. CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1. c. Measure the intake air pressure sensor output voltage.ELECTRICAL COMPONENTS sor shaft.25V MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28360 CHECKING THE EXUP SERVO MOTOR 1. Check: G Intake air pressure sensor output voltage Out of specification → Replace.) EWA14110 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL WARNING the intake air temperature sensor with special care. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Intake air pressure sensor output voltage 3. Check: G EXUP servo motor operation Out of specification → Replace. Disconnect the EXUP cables from the EXUP servo motor pulley. Set the main switch to “ON”. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28420 1 2 d. perform this test within a few seconds of connecting the battery. b.75–4.0 V EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Remove: G Intake air temperature sensor (from the air filter case. Throttle position sensor output voltage 0. The voltage does not change or it changes abruptly → Replace the throttle position sensor. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler (wire harness side) as shown. ECA14390 CAUTION: To prevent damaging the EXUP servomotor. check that the throttle position sensor voltage is within the specified range. Digital circuit tester 90890–03174 Model 88 Multimeter with tachometer YU-A1927 Positive tester probe Pink/White “1” Negative tester probe Black/Blue “2” a. c. Check that the EXUP servo motor pulley rotates several times.

ELECTRICAL COMPONENTS sensor to strong shocks. b. Measure the intake solenoid resistance. If the intake air temperature sensor is dropped. 8-81 . 2.21–2. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 1 2 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS32D1013 CHECKING THE INTAKE SOLENOID 1.69 kΩ 20°C a. Intake solenoid resistance 42–48Ω 20°C MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Connect the pocket tester (Ω × 10) to the intake solenoid terminal as shown. Check: G Intake air temperature sensor resistance Out of specification → Replace. Disconnect the intake solenoid coupler from the wire harness. replace it. Digital circuit tester 90890–03174 Model 88 Multimeter with tachometer YU-A1927 Positive tester probe Brown/White “1” Negative tester probe Black/Blue “2” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Pocket tester 90890-03112 Analog pocket tester YU-03112-C Tester positive lead Red/White “1” Tester negative lead Brown/Black “2” 2 1 c. Intake air temperature sensor resistance 2. Check: G Intake solenoid resistance Out of specification → Replace. Connect the pocket tester (Ω × 1k) to the intake air temperature sensor terminal as shown.

..............................9-3 FAULTY FRONT FORK LEGS.....................................................................................................................................................................................................................................................9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE..9-2 FAULTY CLUTCH ......................................................................................9-2 JUMPS OUT OF GEAR .....................9-2 OVERHEATING ...................................9-1 INCORRECT ENGINE IDLING SPEED ......................................................................................................................................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM.9-2 FAULTY GEAR SHIFTING....................9-1 STARTING FAILURES....................................................9-3 UNSTABLE HANDLING.................................................................................................................................................9-2 SHIFT PEDAL DOES NOT MOVE.................................................................TROUBLESHOOTING TROUBLESHOOTING ..............9-2 OVERCOOLING...............................................9-1 GENERAL INFORMATION ......................9-3 1 2 3 4 5 6 7 8 9 .................................................................9-3 POOR BRAKING PERFORMANCE.......................

Ignition system G ECU failure. Air filter G Improperly installed air filter G Clogged air filter element 4. Fuel cock G Clogged or damaged fuel hose 4. Battery G Discharged battery G Faulty battery 2. Battery G Discharged battery G Faulty battery 2. Starting system G Faulty starter motor G Faulty starter relay G Faulty starting circuit cut-off relay G Faulty starter clutch EAS28490 INCORRECT ENGINE IDLING SPEED Engine 1. damaged or incorrect fuse G Improperly installed fuse 3. worn or fatigued piston ring G Seized piston ring G Seized or damaged piston 3.TROUBLESHOOTING EAS28450 TROUBLESHOOTING EAS28460 GENERAL INFORMATION NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. Fuse (s) G Blown. Cylinder (s) and cylinder head (s) G Loose spark plug G Loose cylinder head or cylinder G Damaged cylinder head gasket G Damaged cylinder gasket G Worn or damaged cylinder G Incorrect valve clearance G Improperly sealed valve G Incorrect valve-to-valve-seat contact G Incorrect valve timing G Faulty valve spring G Seized valve 2. Air filter G Clogged air filter element Fuel system 1. G Faulty crankshaft position sensor G Broken generator rotor woodruff key 6. Fuel tank G Empty fuel tank G Deteriorated or contaminated fuel 2. Piston (s) and piston ring (s) G Damaged. Throttle body G Clogged pilot air passage Electrical system 1. It should be helpful. as a guide to basic troubleshooting. Ignition coil (s) G Cracked or broken ignition coil body G Broken or shorted primary or secondary coils 5. and replacement of parts. Switches and wiring G Defective lean angle sensor G Faulty main switch G Faulty engine stop switch G Broken or shorted wiring G Faulty neutral switch G Faulty start switch G Faulty sidestand switch G Faulty clutch switch G Improperly grounded circuit G Loose connections 7. adjustments. EAS28470 STARTING FAILURES Engine 1. however. Cylinder (s) and cylinder head (s) G Incorrect valve clearance G Damaged valve train components 2. Crankcase and crankshaft G Improperly assembled crankcase G Seized crankshaft Fuel system 1. Throttle body G Air intake in throttle body joint G Improper throttle cable free play G Faulty air induction system Electrical system 1. Refer to the relative procedure in this manual for checks. Spark plug (s) G Incorrect spark plug gap G Incorrect spark plug heat range G Fouled spark plug G Worn or damaged electrode G Worn or damaged insulator 9-1 . Fuel pump G Faulty fuel pump 3. Spark plug (s) G Incorrect spark plug gap G Incorrect spark plug heat range G Fouled spark plug G Worn or damaged electrode G Worn or damaged insulator 4.

Water pump G Damaged or faulty water pump G Faulty thermostat G Damaged fan motor or disconnected coupler G Damaged hose G Improperly connected hose G Damaged pipe G Improperly connected pipe Fuel system 1. Ignition system G ECU failure. Fuel pump G Faulty fuel pump 2. Clutch G Improperly assembled clutch G Loose or fatigued clutch spring G Worn friction plate G Worn clutch plate 2. ECU G ECU failure. EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to “Clutch drags”. Throttle body G Defective throttle body 3. EAS28540 FAULTY CLUTCH Clutch slips 1. G Faulty crankshaft position sensor G EAS28520 EAS28560 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES” on page 9-1. Engine oil G Incorrect oil level G Incorrect oil viscosity (low) G Deteriorated oil Clutch drags 1.TROUBLESHOOTING Faulty spark plug cap 3. Radiator G Damaged or leaking radiator G Faulty radiator cap G Bent or damaged radiator fin 3. Cylinder head (s) and piston (s) G Heavy carbon buildup 2. Coolant G Low coolant level 2. Air filter G Clogged air filter element Fuel system 1. Clutch G Unevenly tensioned clutch springs G Warped pressure plate G Bent clutch plate G Swollen friction plate G Bent clutch push rod G Broken clutch boss G Burnt primary driven gear bushing 2. Engine oil G Incorrect oil level G Incorrect oil viscosity (high) G Deteriorated oil EAS28590 SHIFT PEDAL DOES NOT MOVE Shift shaft G Bent shift shaft Shift drum and shift forks G Foreign object in a shift drum groove G Seized shift fork G Bent shift fork guide bar Transmission G Seized transmission gear G Foreign object between transmission gears G Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft G Incorrect shift pedal position G Improperly returned stopper lever Shift forks G Worn shift fork Shift drum G Incorrect axial play G Worn shift drum groove Transmission G Worn gear dog OVERHEATING Engine 1. Engine oil G Incorrect oil level G Incorrect oil viscosity G Inferior oil quality Cooling system 1. Engine 1. Throttle body G Air intake in throttle body joint 2. Ignition coil (s) G Faulty ignition coil G Cracked or broken ignition coil 4. Air filter 9-2 .

Front fork leg (s) G Uneven oil levels (both front fork legs) G Unevenly tensioned fork spring (both front fork legs) G Broken fork spring G Bent or damaged inner tube G Bent or damaged outer tube 4. Ignition system G ECU failure G Faulty radiator fan motor relay G Faulty coolant temperature sensor G EAS28610 EAS28690 OVERCOOLING Cooling system 1. Thermostat G Thermostat stays open EAS28620 POOR BRAKING PERFORMANCE G Worn brake pad G Worn brake disc G Air in hydraulic brake system G Leaking brake fluid G Defective master cylinder kit G Faulty brake caliper kit G Faulty brake caliper seal G Loose union bolt G Damaged brake hose G Oil or grease on the brake disc G Oil or grease on the brake pad G Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil G Bent. Brake (s) G Dragging brake Electrical system 1.TROUBLESHOOTING Clogged air filter element Chassis 1. Steering head components G Improperly installed upper bracket G Improperly installed lower bracket (improperly tightened ring nut) G Bent steering stem G Damaged ball bearing or bearing race 3. Tire (s) G Uneven tire pressures (front and rear) G Incorrect tire pressure G Uneven tire wear 7. Handlebar G Bent or improperly installed handlebar 2. Swingarm G Worn bearing or bushing G Bent or damaged swingarm 5. Rear shock absorber assembly (-ies) G Faulty rear shock absorber spring G Leaking oil or gas 6. damaged or rusty inner tube G Cracked or damaged outer tube G Improperly installed oil seal G Damaged oil seal lip G Incorrect oil level (high) G Loose damper rod assembly bolt G Damaged damper rod assembly bolt copper washer G Cracked or damaged cap bolt O-ring Malfunction G Bent or damaged inner tube G Bent or damaged outer tube G Damaged fork spring G Bent or damaged damper rod G Incorrect oil viscosity G Incorrect oil level UNSTABLE HANDLING 1. Frame G Bent frame G Damaged steering head pipe G Improperly installed bearing race EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not come on G Fuse open circuit G Wrong headlight bulb G Too many electrical accessories G Hard charging G Incorrect connection G Improperly grounded circuit G Poor contacts (main or light switch) G Burnt-out headlight bulb Headlight bulb burnt out G Wrong headlight bulb G Faulty battery G Faulty rectifier/regulator G Improperly grounded circuit 9-3 . Wheel (s) G Incorrect wheel balance G Broken or loose spoke G Damaged wheel bearing G Bent or loose wheel axle G Excessive wheel runout 8. Spark plug (s) G Incorrect spark plug gap G Incorrect spark plug heat range 2.

TROUBLESHOOTING main switch bulb life expired Tail/brake light does not come on G Too many electrical accessories G Incorrect connection Turn signal does not come on G Fuse open circuit G Faulty turn signal switch G Faulty turn signal relay G Burnt-out turn signal bulb G Incorrect connection G Damaged or faulty wire harness G Improperly grounded circuit G Faulty battery G Blown. damaged or incorrect fuse G Faulty wire harness G Headlight G Faulty 9-4 . damaged or incorrect fuse Turn signal blinks slowly G Faulty turn signal relay G Faulty main switch G Faulty turn signal switch G Incorrect turn signal bulb Turn signal remains lit G Faulty turn signal relay G Burnt-out turn signal bulb Turn signal blinks quickly G Incorrect turn signal bulb G Faulty turn signal relay G Burnt-out turn signal bulb Horn does not sound G Improperly adjusted horn G Damaged or faulty horn (Coil open circuit or damaged terminal) G Faulty main switch G Faulty horn switch G Faulty battery G Blown.

TROUBLESHOOTING 9-5 .

Radiator fan motor relay 53.Starter motor 8.Neutral switch 14.Rear right turn signal light 39.Start switch 11.Signal fuse 56.Rear brake switch 49.Horn 46.Turn signal switch 38.Front right turn signal/position light 40.EAS28740 WIRING DIAGRAM WR250R(X)/WR250X(X) 2008 WIRING DIAGRAM 1.ECU (electronic control unit) 17.Radiator fan motor 54.Headlight 45.Fuel injector 21.Headlight fuse 55.AC magneto 2.Tail/brake light 51.Engine trouble warning light 33.Spark plug 19.Main switch 4.Relay unit 12.Fuel level warning light 34.License plate light 52.Speed sensor 25.Headlight relay 43.Lean angle sensor 28.Intake solenoid 20.Starter relay 7.Ignition fuse 57.Fuel pump 16.High beam indicator light 35.Dimmer switch 44.Battery 5.Neutral indicator light 31.Front brake light switch 50.Radiator fan fuse 58.Rectifier/regulator 3.Main fuse 6.Ignition coil 18.Coolant temperature sensor 24.Engine stop switch 10.Turn signal relay 37.Intake air pressure sensor 27.Air induction solenoid 22.Sidestand switch 13.Meter assembly 30.Throttle position sensor 26.Coolant temperature warning light 32.Backup fuse EAS28750 COLOR CODE B Br Ch Dg G Gy L O P R Sb W Y B/G B/L B/R B/W B/Y Br/G Br/L Br/R Br/W G/B G/R G/W G/Y Gy/G Gy/R Gy/Y L/B L/R L/W L/Y O/B P/W R/B R/G R/L R/W R/Y Sb/W W/B W/R W/Y Y/B Y/G Y/L Y/R Black Brown Chocolate Dark green Green Gray Blue Orange Pink Red Sky blue White Yellow Black/Green Black/Blue Black/Red Black/White Black/Yellow Brown/Green Brown/Blue Brown/Red Brown/White Green/Black Green/Red Green/White Green/Yellow Gray/Green Gray/Red Gray/Yellow Blue/Yellow Blue/Red Blue/White Blue/Yellow Orange/Black Pink/White Red/Black Red/Green Red/Blue Red/White Red/Yellow Sky blue/White White/Black White/Red White/Yellow Yellow/Black Yellow/Green Yellow/Blue Yellow/Red .Fuel injection system fuse 59.Left handlebar switch 48.Clutch switch 15.Intake air temperature sensor 23.Rear left turn signal light 42.Turn signal indicator light 36.Front left turn signal/position light 41.Horn switch 47.Right handlebar switch 9.EXUP servo motor 29.

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.YAMAHA MOTOR CO. LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN .

WR250RX/WR250XX 2008 WIRING DIAGRAM WR250RX/WR250XX 2008 SCHÉMA DE CÂBLAGE WR250RX/WR250XX 2008 SCHALTPLAN SCHEMA ELETTRICO WR250RX/WR250XX 2008 DIAGRAMA ELÉCTRICO DE LA WR250RX/WR250XX 2008 .

WR250RX/WR250XX 2008 WIRING DIAGRAM WR250RX/WR250XX 2008 SCHÉMA DE CÂBLAGE WR250RX/WR250XX 2008 SCHALTPLAN SCHEMA ELETTRICO WR250RX/WR250XX 2008 DIAGRAMA ELÉCTRICO DE LA WR250RX/WR250XX 2008 .