TW200N TW200NC

LIT-11616-14-43

SUPPLEMENTARY SERVICEMANUAL
2YG-28197-11

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the TW200EN/TW200ENC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. TW200T/TC ’87 SERVICE MANUAL: LIT-11616-05-93 (2JX-28197-10) TW200EU/EUC ’88 SUPPLEMENTARY SERVICE MANUAL: LIT-11616-06-26 (2YG-28197-10)

TW200N/TW200NC SUPPLEMENTARY SERVICE MANUAL © 2000 by Yamaha Motor Corporation, U.S.A. First edition, November 2000 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-11616-14-43

EAS00003

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

EAS00004

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 motorcycle operator, a bystander or a person checking or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.

CAUTION:
NOTE:

etc. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. 2 Each chapter is divided into sections. removal. 7 A job instruction chart accompanies the exploded diagram. Refer to “SYMBOLS”. 6 Symbols indicate parts to be lubricated or replaced.EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy. where the sub-section title(s) appears. The current section title is shown at the top of each page. 5 Numbers are given in the order of the jobs in the exploded diagram. 3 Sub-section titles appear in smaller print than the section title. Comprehensive explanations of all installation. 1 The manual is divided into chapters. . providing the order of jobs. Refer to “SYMBOLS”. names of parts. repair and check procedures are laid out with the individual steps in sequential order. there are exploded diagrams at the start of each removal and disassembly section. easy-to-read reference book for the mechanic. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially. except in chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”). A circled number indicates a disassembly step. notes in jobs. assembly. disassembly. 4 To help identify parts and clarify procedure steps.

LT New M Apply locking agent (LOCTITE®) N Replace the part . D R. clearance E Engine speed F Electrical data A B C T. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Chassis 7 Electrical system 8 Troubleshooting GEN INFO 3 SPEC 4 CHK ADJ 5 ENG 6 CARB 7 – + CHAS 8 ELEC 9 TRBL SHTG 0 Symbols 9 to F indicate the following. Symbols 1 to 8 indicate the subject of each chapter. 9 Serviceable with engine mounted 0 Filling fluid A Lubricant B Special tool C Tightening torque D Wear limit. E F G H I Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points.1 2 EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. M G Engine oil H Gear oil I Molybdenum disulfide oil J Wheel bearing grease K Lithium soap base grease L Molybdenum disulfide grease E J B G K LS L M M N Symbols M to N in the exploded diagrams indicate the following.

.................................................................................................................. 31 CARBURETION .................................................... 25 CHECKING THE BRAKE HOSE ..................... 32 CARBURETOR .................................................................. 21 ADJUSTING THE THROTTLE CABLE FREE PLAY ....................................................................................................................................................................................................................................... 29 AC MAGNETO ............................. 22 CHASSIS ................................. 10 PERIODIC CHECKS AND ADJUSTMENTS ................................... 29 INSTALLING THE TIMING CHAIN TENSIONER .................................................... 30 STATOR COIL ASSEMBLY AND PICKUP COIL ............................................................................................................................................. 28 CYLINDER HEAD ...................................... 1 MODEL CODE ............................... 4 TIGHTENING TORQUESS .......................... 37 INSTALLING THE CARBURETOR ................................... 2 GENERAL SPECIFICATIONS ...................................................... 1 SPECIFICATIONS .......................................................................................................................................................................................... 35 ASSEMBLING THE CARBURETOR ........................... 32 DISASSEMBLING THE CARBURETOR ............................................... 21 CLEANING THE SPARK ARRESTER .......... 30 AC MAGNETO ......................................... 1 MOTORCYCLE IDENTIFICATION ................................................................... 38 MEASURING AND ADJUSTING THE FUEL LEVEL ...................................................................... 8 ELECTRICAL ...................................................... 18 INTRODUCTION ...................................CONTENTS GENERAL INFORMATION................................................................................................................................................................. 39 ....................................................... 9 CABLE ROUTING ...................... 26 ENGINE........................................................... 7 TIGHTENING TORQUESS ...................................................................................................................................... 18 GENERAL MAINTENANCE AND LUBRICATION CHART ...... 23 ADJUSTING THE FRONT BRAKE ................................. 1 VEHICLE IDENTIFICATION NUMBER .................................. 18 PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM ... 6 CHASSIS ................... 25 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................................................. 35 CHECKING THE CARBURETOR ............................................................................. 2 MAINTENANCE SPECIFICATIONS ................ 19 ENGINE ..................................................................................... 23 CHECKING THE BRAKE FLUID LEVEL .......................................................................................................................... 24 CHECKING THE BRAKE PADS ................................................................................................................................... 28 CHECKING THE TIMING CHAIN TENSIONER ....................................... 4 ENGINE ............

........... 81 CIRCUIT DIAGRAM ................................... 52 ASSEMBLING AND INSTALLING THE FRONT BRAKE MATER CYLINDER ................................................................................................................................... 75 CIRCUIT DIAGRAM ............................................ 42 CHECKING THE BRAKE DISC .............................................................. 55 DISASSEMBLING THE FRONT BRAKE CALIPER ......................... 50 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER . 47 FRONT BRAKE MASTER CYLINDER ................. 59 FRONT FORK ........................................................................................................................................................ 76 TROUBLESHOOTING ........ 81 TROUBLESHOOTING ...... 44 FRONT BRAKE ................. 83 TW200EN/TW200ENC WIRING DIAGRAM .................. 77 SIGNALING SYSTEM ...................................................... 66 SWITCHES .............. 82 CHECKING THE SIGNALING SYSTEM ................................................................................................................................................................................................................................................................................................................................................................................................................................. 46 FRONT BRAKE PADS .................. 62 STEERING HEAD .................CHASSIS ....... 71 ELECTRIC STARTING SYSTEM .................................................................................................................................................................................. 58 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS .............................................................................................................................................................. 53 FRONT BRAKE CALIPER ................................................................................................................................... 66 ELECTRICAL COMPONENTS ....................................................... 52 CHECKING THE FRONT BRAKE MASTER CYLINDER ................................. 67 CHECKING THE SWITCHES ............................... 70 TROUBLESHOOTING ........................................................................ 63 INSTALLING THE BEARING (RETAINER TYPE) ..... 67 CHECKING SWITCH CONTINUITY ..................................................... 46 REPLACING THE FRONT BRAKE PADS ..................................................................................... 40 FRONT WHEEL AND BRAKE DISC ................................ 70 CIRCUIT DIAGRAM ............................................. 42 INSTALLING THE FRONT WHEEL ............................................................... 75 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........... 65 ELECTRICAL............................................................................. 40 REMOVING THE FRONT WHEEL ..... 68 IGNITION SYSTEM .. 57 CHECKING THE FRONT AND REAR BRAKE CALIPERS .....................

–1– .MOTORCYCLE IDENTIFICATION EAS00014 GEN INFO GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. This information will be needed to order spare parts. EAS00018 MODEL CODE The model code label 1 is affixed to the frame.

638 × 2.04 in)> –2– .) 0. X24ESR-U (N.96 cu.3 in) 1.120 mm (44.8° 95 mm (3.D.028 in) Diamond 25.7 mm (0.193 in) 9.3 in) 820 mm (32.1 in) 790 mm (31.2 in) 265 mm (10.024 ~ 0.0 mm (0. SOHC Forward inclined single cylinder 196 cm3 (11.in) 67.6 ~ 0.4 in) Air cooled 4-stroke.1 in) 1.0 × 55.74 in) With tube 130/80-18 66P TW31 180/80-14M/C 78P TW34 <1.090 mm (82.7 mm (2.5 : 1 900 kPa (9 kg/cm2.GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code number: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Compression pressure (standard) Starting system Carburetor: Type/manufacturer Spark plug: Type/manufacturer Gap Chassis: Frame type Caster angle Trail Tire: Type Size (F) Size (R) Wear Limit TW200EN/TW200ENC TW200EN: 5FY8 TW200ENC: 5FY9 2.325 mm (52. 128 psi) Electric starter MV28/TEIKEI DR8EA (NGK).

3.25 kg/cm2. 60 W/55 W × 1 12 V. 27 W × 2 12 V. –3– .25 kg/cm2. 127 kg (280 lb) (TW200ENC) 157 kg (346 lb)/(TW200EN). 22 psi) (1.5 kg/cm . 25 psi) Single disc brake Right hand operation Drum brake Right foot operation Coil spring/oil damper Gas and coil spring/oil damper 12 V.5 kg/cm2.GENERAL SPECIFICATIONS Model Basic weight: With oil and full fuel tank Maximum load* Cold tire pressure: Up to 80 kg (176 lb) load* 80 kg (176 lb) ~ Maximum load* Off-road riding High speed riding Brake: Front brake type Operation Rear brake type Operation Shock absorber: Front shock absorber Rear shock absorber Bulb wattage/quantity: Headlight Tail/brake light Front turn signal/position light Rear turn signal light Meter light SPEC TW200EN/TW200ENC 126 kg (278 lb)/(TW200EN).4 W × 1 * Load is the total weight of cargo. 25 psi) 125 kPa 125 kPa 2 (1. 22 psi) (1. 8 W/27 W × 2 12 V. 18 psi) 150 kPa 175 kPa 2 (1.75 kg/cm2. 18 psi) (1. 156 kg (344 lb) (TW200ENC) Front Rear 125 kPa 125 kPa (1. rider. 27 W/8 W × 2 12 V.75 kg/cm2. passenger and accessories. 18 psi) (1.25 kg/cm .25 kg/cm2. 18 psi) 150 kPa 175 kPa (1.

02 ~ 0.0008 ~ 0.0012 in)> Cam chain type/number of links Cam chain adjustment method Piston ring: Sectional sketch: Top ring T DID 25SH/104 links Automatic B 2nd ring B T Oil ring T B End gap (Installed): Side clearance Top ring 2nd ring Oil ring Top ring 2nd ring Barrel B = 1.191 in) 6.047 in) T = 2.444 in) 30.07 mm (0.252 mm (1.983 ~ 0.440 ~ 1.538 ~ 36.012 in) 0.110 in) 0.006 ~ 0.984 in) 0.000 ~ 25.03 mm (0.192 ~ 1.588 mm (0.9 mm (0.003 in) 0.58 ~ 36.MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Camshaft: Drive method Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Cam dimensions: Intake: “A” “B” C “C” A Exhaust: “A” “B” B “C” Camshaft runout limit SPEC TW200EN/TW200ENC Chain drive (left) 25.98 mm (0.7 mm (0.63 mm (0.014 in) 0.8 mm (0.15 ~ 0.061 mm (0.06 mm (0.266 ~ 30.96 ~ 24.0024 in) 36.098 in) T = 2.187 ~ 1.2 mm (0.020 ~ 0.261 in) <0.35 mm (0.68 mm (1.15 ~ 0.30 mm (0.021 mm (0.006 ~ 0.152 ~ 30.196 in) 6.7 mm (0.259 in) 36.3 ~ 0.442 in) 30.012 ~ 0.002 in) –4– .439 ~ 1.035 in) 0.106 in) Expander B = 2.047 in) T = 2.001 ~ 0.985 in) 24.2 mm (0.106 in) Taper B = 1.638 mm (1.5 mm (0.984 ~ 0.001 ~ 0.366 mm (1.03 ~ 0.

) (G.A.0 0.6 0.) Float height Engine idling speed Vacuum pressure at idling speed 10 ~ 11 mm (0.S.S1.3 ~ 34.43 in) 1.300 ~ 1.06 in) (V.8 0.) (P.L.) (J.) (G.J.6 0.500 r/min 29.600 #31 TW200EN: 0.2 TW200EN: 5B21-1/1 TW200ENC: 5B21-1/3 2.02 ~ 0.5 mm (0.8 0.S2. 8.MAINTENANCE SPECIFICATIONS Model Carburetor: ID mark Main jet Main air jet Jet needle-clip/position Main nozzle Pilot jet Pilot air jet Pilot outlet Bypass Valve seat Starter jet (M.5 ~ 1.N) (M.) Fuel level (above the line on the float chamber mating surface) (F.66 ~ 10.7 kPa (220 ~ 260 mmHg.J.A.) SPEC TW200EN/TW200ENC TW200EN: 5FY10 TW200ENC: 5FY00 TW200EN: #126 TW200ENC: #128 1.) (M.95 TW200ENC: 1.J.N.) (P.39 ~ 0.J.7 1.24 inHg) or more –5– .

2 7.0 1.0 1.0 7.2 7.0 1.2 Apply LOCTITE® 7.1 7.2 Apply LOCTITE® 7.0 1.2 7.7 1.2 7.2 Apply LOCTITE® –6– .0 1.2 7.2 5.0 0.2 7.0 1.MAINTENANCE SPECIFICATIONS TIGHTENING TORQUESS Thread Part name Q’ty size Bolt Bolt Bolt Bolt Screw Bolt Bolt Bolt Bolt Bolt Bolt M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 2 5 2 2 4 12 9 12 1 2 3 Tightening torque SPEC Parts to be tightened Cam sprocket cover Tappet cover Timing chain tensioner Oil filter cover Muffler protector Crankcase Crankcase cover (left) Crankcase cover (right) Pickup coil lead holder Pickup coil Stator coil assembly Remarks Nm m·kg ft·lb 10 10 10 10 7 10 10 10 10 10 10 1.0 1.0 1.

33 in) <111 mm (4.39 ~ 0.21 in) <0.08 in)> 50.2 in) 15 mm (0.3 mm (0.6 in) (Vertical height below footrest top.) 10 ~ 15 mm (0. deflection Brake pad lining thickness <Limit> Master cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Rear brake: Brake type Drum inside dia.43 in) 26.8 ~ 1.03 in)> 11 mm (0.2 mm (0.08 ~ 0.16 in) <2 mm (0.15 mm (0.36 in) SPEC TW200EN/TW200ENC Single-disc brake 220 × 3.006 in) 5.06 in) + 22.66 × 0.59 in) –7– .9 mm (1.5 mm (8.99 in) 2 ~ 5 mm (0.5 mm (1. <Limit> Lining thickness Front <Limit> Shoe spring free length Brake lever and brake pedal: Brake lever free play (at lever end) Brake pedal free play (at pedal end) Brake pedal position Clutch lever free play (at lever end): Angular ball 428HG (I)/DAIDO 121 links + joint 35 ~ 60 mm (1.20 in) 20 ~ 30 mm (0.37 in)> 4 mm (0.87 in) DOT4 Drum brake (leading and trailing) 110 mm (4.14 in) 0.8 mm (0.38 ~ 2.MAINTENANCE SPECIFICATIONS CHASSIS Model Steering system: Steering bearing type Drive chain: Type/manufacturer Number of links Chain free play Front brake: Brake type Disc outside diameter × thickness Max.

4 22 19 22 4.25 M25 × 1. NOTE: 1.6 60 41 3. tighten the ring nut to approximately 38 Nm (3.6 Remarks See NOTE.25 M10 × 1.3 5.0 M6 × 1.0 1.0 SPEC Tightening torque Nm 5 83 56 5 20 18 7 13 30 27 30 6 15 5 m·kg 0.25 M10 × 1. 2.3 3.6 0.8 0.5 2.6 1.1 9.0 M12 × 1. then loosen the ring nut completely.25 M5 × 0.0 M8 × 1.25 M7 × 1. First. –8– .8 m • kg. Retighten the ring nut to specification.0 M10 × 1.MAINTENANCE SPECIFICATIONS TIGHTENING TORQUESS Parts to be tightened Throttle cable and carburetor Pivot shaft and frame Rear shock absorber and frame Drive chain case and swingarm Handlebar holder upper and upper bracket Steering shaft and ring nut Front brake master cylinder and handlebar Front wheel hub and brake disc Front brake caliper bracket and outer tube Front brake caliper and caliper bracket Brake hose union bolt Air bleeder screw Passenger footrest and frame Rear fender and cover Thread size M6 × 1.8 M8 × 1.7 1.25 M6 × 1.6 14 13 5.3 11 3.5 8.25 M10 × 1.0 M6 × 1.5 0.5 ft·lb 3.0 0. 27 ft • lb) with a torque wrench.0 2.7 3.

MAINTENANCE SPECIFICATIONS ELECTRICAL Model C.4 W Fuse 20 A –9– .017 ~ 0.D. magneto generator 5FBT/YAMAHA 0.28 Ω at 20 °C (68 °F) 6.7 Ω at 20 °C (68 °F) (W–W) Semi conductor type SH629A-12/SHINDENGEN 14.18 ~ 0.5 mm (0.6 oz) <450 g (0.3 ~ 9.I.24 IN) or more at 500 r/min 0.I. 75 ~ 95 cycle/min 27 W × 2 + 3.14 in)> 560 ~ 840 g (19. unit-model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Charging system: Type Model/manufacturer Charge coil resistance (color) Rectifier/regulator: Type Model/manufacturer No load regulated voltage Capacity Withstand voltage Starter motor: Model/manufacture Output Armature coil resistance Brush overall length <Limit> Brush spring pressure <Limit> Commutator dia.5 kΩ at 20 °C (68 °F) A. <Limit> Mica undercut Flasher relay: Type Model/manufacturer Self cancelling device Flasher frequency Wattage Circuit breaker: Type Amperage for individual circuit Main SPEC TW200EN/TW200ENC F5BT/YAMAHA 656 ~ 984 Ω at 20 °C (68 °F) (R–W) 624 ~ 936 Ω at 20 °C (68 °F) (Br–G) 5LB/YAMAHA 2JN/YAMAHA 6 mm (0.9 V 10 A 200 V 5FY/YAMAHA 0.8 ~ 29.1 ~ 14.39 in) <3.4 kW 0.021 Ω 10 mm (0.5 mm (0.: Magneto model/manufacturer Pickup coil resistance (color) Source coil resistance (color) C.98 oz)> 22 mm (0.D.C.87 in) <21 mm (0.83 in)> 1.5 ~ 0.06 in) Full transistor FE246BH/DENSO No.

É Fasten the wire harness with a plastic locking tie. – 10 – .CABLE ROUTING CABLE ROUTING 1 Throttle cable 2 Front brake light switch lead 3 Right handlebar switch lead 4 Clutch cable 5 Left handlebar switch lead 6 Clutch switch lead 7 Front turn signal/position light lead (left) 8 Main switch lead 9 Indicator lights lead 0 Speedometer cable A Meter light lead B Headlight coupler C Wire harness D Front turn signal/position light lead (right) E Brake hose SPEC È Fasten the brake hose with a plastic locking tie to the brake hose grommet.

– 11 – . Ì Fasten the brake hose with a plastic locking tie to the brake hose grommet. É Pass the canister hose through the guide of the frame. (for California) Ê Fasten the resonator hose with a plastic band in front of the resonator hose protector. Ë Fasten the rectifier/regulator lead and resonator hose with a plastic band between the resonator hose protectors so that the fastener does not squeeze the hose.CABLE ROUTING 1 Clutch cable 2 Left handlebar switch lead 3 Clutch switch lead 4 Resonator hose 5 Main switch lead 6 Rectifier/regulator lead 7 Fuel hose 8 Brake hose 9 Speedometer cable 0 Horn lead SPEC È Fasten the resonator hose with a plastic band between the resonator hose protectors so that the fastener does not squeeze the hose.

and neutral switch lead with a plastic clip.CABLE ROUTING 1 Sidestand switch lead 2 Crankcase breather hose 3 Battery negative terminal 4 Carburetor air vent hose 5 Carburetor overflow hose 6 AC magneto lead 7 Starter motor lead 8 Neutral switch lead SPEC È Fasten the AC magneto leads with a plastic locking tie to the frame at the section where the frame starts to curve. – 12 – . É Fasten the carburetor air vent hose. carburetor overflow hose.

Ê Fasten the throttle cable and canister hose with a plastic clip. (for California) Ë Fasten the throttle cable with a plastic locking tie through the hole in the frame bracket. main switch lead. right handlebar switch lead. main switch lead. clutch switch lead. front brake light switch lead. É Fasten the wire harness. – 13 – . clutch switch lead. Be sure to face the ends of the clip downward from the frame. and throttle cable with a plastic band. right handlebar switch lead. front brake light switch lead.CABLE ROUTING 1 Ignition coil 2 Throttle cable 3 Horn lead 4 Canister hose (for California) 5 Canister (for California) 6 Spark plug 7 Starter motor lead SPEC È Fasten the wire harness. and resonator hose with a plastic band.

CABLE ROUTING SPEC Ì Fasten the wire harness. ground lead. and horn lead with a plastic band. (for California) Î Pass the canister hose through the engine stay guide. Í Fasten the canister hose with a plastic band. resonator hose. ignition coil lead. clutch switch lead. front brake light switch lead. main switch lead. right handlebar switch lead. (for California) – 14 – .

Ë Fasten the rear brake light switch lead and turn signal relay lead with a plastic locking tie. É Pass the battery breather hose inside the battery positive lead.CABLE ROUTING 1 Diode 2 Battery positive lead 3 Starter relay 4 Starter motor lead 5 CDI unit 6 Wire harness 7 Turn signal relay SPEC È Fasten the wire harness with a plastic locking tie at the section just before the leads split. Ê Pass the rear brake light switch lead in front of the frame so that it is not squeezed by the side cover and frame. Ì Face the rear brake light switch lead to the rear of the frame. Í Pass the battery breather hose through the hose guide. Ï Fasten the wire harness and diode with a plastic locking tie. Î Pass the battery breather hose through the hole in the electrical components box. – 15 – .

È Fasten the right handlebar switch lead and front brake light switch lead with a plastic band. and battery negative lead with a plastic locking tie by passing the tie through the hole in the frame bracket. neutral switch lead. É Fasten the AC magneto leads. starter motor lead. – 16 – .CABLE ROUTING 1 Clutch switch lead 2 Clutch cable 3 Brake hose 4 Throttle cable 5 Front brake light switch lead 6 Right handlebar switch lead 7 Starter motor lead 8 AC magneto lead 9 Rectifier/regulator 0 Battery negative lead A Neutral switch lead B Left handlebar switch lead SPEC Ê Fasten the left handlebar switch lead and clutch switch lead with a plastic band.

É Fasten the rear turn signal light lead (left) with a plastic locking tie.CABLE ROUTING 1 Battery positive lead 2 Rear turn signal light lead (right) 3 Tail/brake light lead 4 Rear turn signal light lead (left) 5 Sidestand switch lead 6 Battery negative lead 7 AC magneto lead 8 Neutral switch lead 9 Starter motor lead SPEC È Fasten the wire harness and rear turn signal light lead (right) with a plastic locking tie at the section behind the hook. – 17 – .

• Replace if necessary.000 mi (21.INTRODUCTION/PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM INTRODUCTION CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS This chapter includes all information necessary to perform recommended checks and abjustments.000 km) or 18 month 13. repeat the maintenance intervals starting from 4. • Retighten if necessary. • Check condition. • Replace gaskets if necessary.This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. • Check and adjust engine idle speed.000 km) or 24 month 1 * Valve clearance • Check and adjust valve clearance when engine is cold. a longer service life and reduce the need for costly overhaul work.000 km) or 6 month ODOMETER READINGS 7. • Clean.000 mi (11. • Replace if necessary.All service technicians should be familiar with this entire chapter. • Adjust gap and clean.000 km (or 12 months) and thereafter every 10. ITEM ROUTINE 600 mi (1. **: California type only. PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM INITIAL No. • Replace at 11. have a Yamaha dealer perform the service.If followed.000 km) or 1 month 4. – 18 – .000 mi (16.000 km (or 12 months). • Check fuel hose for crack or damage. • Adjust cable free play. • Check control system for damage.000 mi (6.000 km) or 30 months. NOTE: From 16.000 km) or 12 month 10. data and technical skills. • Check for leakage.000 mi (6. these preventive maintenance procedures will ensure more reliable vehicle operation. √ √ √ √ √ 2 Spark plug √ Replace √ Replace 3 * Fuel line √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 4 * Exhaust system 5 Spark arrester 6 * Idle speed Evaporative emis7 * sion control system** *: Since these items require special tools.000 mi (26.000 km) or 6 months.

(all-purpose grease) Lithium-soap-based grease. (Front) • Replace shoes if necessary. Lithium-soap-based grease. wheel bearing • Moderately repack grease. • Replace oil filter and strainer if damaged.GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL No. √ √ √ √ 10 √ √ √ √ 11 * Sidestand pivots √ √ √ √ 12 * Front fork √ √ √ √ 13 * Steering bearings • Check bearings assembly for Medium weight looseness. √ √ √ √ √ 4 * Brake system – √ √ √ √ √ 5 * Clutch – √ √ √ √ √ 6 Drive chain • Check chain condiSpecial O-ring chain tion. – √ √ √ 3 * Air filter • Wet type filter must Yamaha foam air filter oil or other quality be washed and air filter oil. Yamaha chain and cable lube or engine oil. damped with oil. • Apply chain lube lightly • Check operation and lubricate.000 km) or 18 month 13. every 10. (all-purpose grease) Lithium-soap-based grease.000 mi (21. (Rear) • Adjust free play.000 km) or 6 month CHK ADJ ODOMETER READINGS 7. Rear arm pivot shaft • Apply until new grease shows.000 mi (16.000 mi (16. 1) Yamalube 4 (20 W 40) or SAE 20 W 40 type “SE/SF” motor oil. • Check operation and leakage. • Adjust free play. (all-purpose grease) – √ √ Every 300 mi (500 km) 7 Control and meter • Apply chain lube cable thoroughly. √ √ √ 8 * √ √ √ √ 9 Brake/clutch lever • Apply chain lube pivot shaft lightly.000 km) or 1 month 4.000 km) or 12 month 10. Brake pedal and shift pedal shaft • Lubricate. • Apply chain lube lightly. • Check fluid leakage. – √ √ Repack √ 14 * Wheel bearings √ √ √ √ – 19 – .000 km) • Check bearings for smooth rotation.) • Correct if necessary. • Replace pads if necessary. (all-purpose grease) Lithium-soap-based grease.000 km) or 24 month 1 Engine oil • Warm-up engine before draining.000 mi (11. ITEM ROUTINE TYPE 600 mi (1. √ √ √ √ √ 2 * Oil filter/strainer • Clean filter element and oil strainer. (Front) (see NOTE. 2) Yamalube 4 (10 W 30) or SAE 10 W 30 type “SE/SF” motor oil. • Adjust and lubricate lubricant chain thoroughly.000 mi (6.

• Check that the breather pipe is working properly.000 mi (6.000 mi (16.000 km) or 18 month 13. NOTE: 1. Hydraulic brake system • Replace the brake fluid after disassembling the master cylinder or caliper cylinder. ITEM ROUTINE TYPE 600 mi (1. • Check the brake fluid level and add fluid as required. The air filter element needs more frequent service if you are riding in unusually wet or dusty areas.000 km) or 1 month 4.000 km) or 6 month 7. – √ √ √ √ 16 * Sidestand switch – √ √ √ √ √ * Since these items require special tools. • Replace the master cylinder and caliper cylinder oil seals every two years.000 km) or 12 month CHK ADJ 10. data and technical skills.000 mi (21. • Replace the brake hoses every four years or if cracked or damaged. 2.000 km) or 24 month ODOMETER READINGS 15 Battery • Check specific gravity. • Correct if necessary. – 20 – . have a Yamaha dealer perform the service.GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL No.000 mi (11. • Check and clean or replace if necessaly.

20 in) 2. Measure: • throttle cable free play a Out of specification → Adjust. – 21 – .12 ~ 0. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. use the adjusting nut on the handlebar side. Adjust: • throttle cable free play wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww Carburetor side a. NOTE: If the specified throttle cable free play cannot be obtained on the carburetor side of the cable. b. 1. Direction a Direction b Throttle cable free play is increased. Tighten the locknut. the engine idling speed should be adjusted properly. Loosen the locknut 1. c.ADJUSTING THE THROTTLE CABLE FREE PLAY ENGINE CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play. Throttle cable free play is decreased.

Direction c Direction d Throttle cable free play is increased. 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. c. Top the tail pipe lightly. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv CLEANING THE SPARK ARRESTER 1. e. Slide back the rubber cover 3.ADJUSTING THE THROTTLE CABLE FREE PLAY/ CLEANING THE SPARK ARRESTER CHK ADJ Handlebar side a. Clean: • Spark arrester wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww WARNING • Do not start the engine when cleaning the exhaust system. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv – 22 – . a. Remove the screw 1. d. Throttle cable free play is decreased. c. Install the screw and tighten it. Insert the tail pipe into the muffler and align the screw hole. then use a wire brush to remove any carbon deposits from the spark arrester 3 portion of the tail pipe. Tighten the locknut. Loosen the locknut 4. b. • Always let the exhaust system cool before performing this operation. d. Turn the adjusting nut 5 in direction c or d until the specified throttle cable free play is obtained. WARNING After adjusting the throttle cable free play. b. Remove the tail pipe 2 by pulling it out of the muffler.

Turn the adjusting bolt 2 in direction a or b until the specified brake lever free play is obtained. the air must be removed by bleeding the brake system. check and. CAUTION: After adjusting the brake lever free play. WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. bleed the brake system. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv – 23 – .08 ~ 0.ADJUSTING THE FRONT BRAKE CHASSIS CHK ADJ ADJUSTING THE FRONT BRAKE 1. Direction a Direction b Brake lever free play is increased.Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident.Therefore. if necessary. Adjust: • brake lever free play a. Brake lever free play (at the end of the brake lever) 2 ~ 5 mm (0.Before the vehicle is operated. Loosen the locknut 1. Check: • brake lever free play a Out of specification → Adjust. wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww c. Tighten the locknut. b. make sure there is no brake drag. Brake lever free play is decreased.20 in) 2.

Therefore. Mixing brake fluids may result in a harmful chemical reaction. • When refilling. NOTE: In order to ensure a correct reading of the brake fluid level. be careful that water does not enter the brake fluid reservoir. leading to poor brake performance. Stand the motorcycle on a level surface. – 24 – . Other brake fluids may cause the rubber seals to deteriorate.Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. • Refill with the same type of brake fluid that is already in the system. NOTE: • Place the motorcycle on a suitable stand.CHECKING THE BRAKE FLUID LEVEL CHK ADJ CHECKING THE BRAKE FLUID LEVEL 1. causing leakage and poor brake performance. make sure that the top of the brake fluid reservoir is horizontal. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. always clean up any spilt brake fluid immediately. • Make sure that the motorcycle is upright. Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. CAUTION: ‘jC Brake fluid may damage painted surfaces and plastic parts. 2.

CHECKING THE BRAKE HOSE The following procedure applies to all of the brake hose and brake hose clamps. Check: • brake hose clamp Loose → Tighten the clamp bolt. Check: • brake hose Brake fluid leakage → Replace the damaged hose. 1. 2. Refer to “REPLACING THE FRONT BRAKE PADS”. 2. Check: • front brake pad Wear indicator groove 1 almost disappeared → Replace the brake pads as a set. Operate the brake. Hold the motorcycle upright and apply the brake several times. 3. 1. Refer to “FRONT BRAKE”. Check: • brake hose 1 Cracks/damage/wear → Replace. 4. – 25 – .CHECKING THE BRAKE PADS/ CHECKING THE BRAKE HOSE CHK ADJ CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads.

Ignoring this precaution could allow air to enter the hydraulic brake system. c. • When bleeding the hydraulic brake system. Install the master cylinder reservoir diaphragm. e. Loosen the bleed screw. • brake operation is faulty. • a brake hose was loosened. Place the other end of the hose into a container. NOTE: • Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow.BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenever: • the brake system was disassembled. b. • If bleeding is difficult. it may be necessary to let the brake fluid settle for a few hours. disconnected or replaced. 1 2 1. considerably lengthening the bleeding procedure. Connect a clear plastic hose 1 tightly to the bleed screw 2. – 26 – . NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip to fully extend. Fully squeeze the brake lever and hold it in position. Bleed: • hydraulic brake system wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww a. • the brake fluid level is very low. d. Slowly apply the brake several times. g. make sure that there is always enough brake fluid before applying the brake. f.Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.

j. WARNING R. After bleeding the hydraulic brake system. check the brake operation. Refer to “CHECKING THE BRAKE FLUID LEVEL”. Tighten the bleed screw to specification. Tighten the bleed screw and then release the brake lever. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv T.3 ft · lb) k. – 27 – . 4. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.6 m · kg. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ h. Bleed screw 6 Nm (0. i.

– 28 – . Refer to “INSTALLING THE TIMING CHAIN TENSIONER”. For installation. Refer to “CARBURETOR”. reverse the removal procedure. 1 1 1 1 1 1/1 1 1 3 1 Disconnect.CYLINDER HEAD ENG ENGINE CYLINDER HEAD Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the cylinder head Carburetor Fuel tank Exhaust pipe Resonator hose Carburetor joint Timing chain tensioner cap bolt Timing chain tensioner Gasket Camshaft sprocket cover/O-ring Camshaft sprocket Cylinder head Dowel pin Gasket Q’ty Remarks Remove the parts in the order listed.

1 wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww a. Install: • timing chain tensioner wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww 1 a.2 ft · lb) R. New 3 2 d. tighten the timing chain tensioner bolts 3 to the specified torque. NOTE: While pressing the timing chain tensioner rod. wind it clockwise with a thin screwdriver 1 until it stops. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv – 29 – . c.If there is rough movement. New 4 T. Check: • timing chain tensioner Cracks/damage/rough movement → Replace. Remove the screwdriver. b. With the screwdriver still inserted into the timing chain tensioner.0 m · kg. 7. Remove the screwdriver and slowly release the timing chain tensioner rod.CYLINDER HEAD ENG CHECKING THE TIMING CHAIN TENSIONER 1. Timing chain tensioner bolt 10 Nm (1. wind it clockwise with a thin screwdriver 1 until it stops. c. install the timing chain tensioner 2 and gasket onto the cylinder block. and tighten the cap bolt 4. replace the timing chain tensioner. Then. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv INSTALLING THE TIMING CHAIN TENSIONER 1. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. b. WARNING Always use a new gasket. While pressing the timing chain tensioner rod. make sure that the timing chain tensioner rod releases.

R. 7.0 m • kg. – 30 – .2 ft • Ib) T.AC MAGNETO AC MAGNETO STATOR COIL ASSEMBLY AND PICKUP COIL ENG 10 Nm (1. R. 7. Order 1 2 3 4 Job/Part Removing the stator coil assembly and pickup coil Engine oil Crankcase cover (left) Lead holder Pickup coil bracket Pickup coil Stator coil assembly Q’ty Remarks Remove the parts in the order listed. 1 LT LT 4 2 LT LT 3 10 Nm (1. reverse the removal procedure. 1 1 1 1 For installation. Drain.0 m • kg.2 ft • Ib) T.

AC MAGNETO AC MAGNETO ENG Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the AC magneto AC magneto Starter idle gear shaft/collar Starter idle gear Woodruff key Starter wheel gear Washer Roller Spring cap Spring Starter clutch Q’ty 1 1/1 1 1 1 1 3 3 3 1 Remarks Remove the parts in the order listed. reverse the removal procedure. For installation. – 31 – .

2 1 1 1 For installation. – 32 – .CARBURETOR CARB CARBURETION CARBURETOR 1 2 3 4 Order 1 2 3 4 Job/Part Removing the carburetor Seat Side cover Fuel tank Throttle cable Clamp (carburetor joint) Clamp (ail filter joint) Carburetor assembly Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure.

make sure to note the number of times the pilot screw is turned out from the seated position to its set position. NOTE: Before disassembling the carburetor.CARBURETOR CARB 3 5 2 4 A C B 0 1 8 D F G E 6 New 7 New 9 (4) Order Job/Part Disassembling the carburetor Q’ty Remarks Remove the parts in the order listed. 1 2 3 4 5 6 7 8 9 Starter plunger Vacuum chamber cover/spring Jet needle holder Piston valve Jet needle kit Coasting enricher cover/spring Coasting enricher Air vent hose/joint Throttle stop screw assembly 1 1/1 1 1 1 1/1 1 1/1 1 – 33 – .

CARBURETOR CARB 3 5 2 4 A C B 0 1 8 D F G E 6 New 7 New 9 (4) Order 0 A B C D E F G Job/Part Float chamber/gasket Float pin Float Needle valve Valve seat set Main jet Pilot jet Main jet nozzle Q’ty 1/1 1 1 1 1 1 1 1 Remarks Refer to “ASSEMBLING THE CARBURETOR”. – 34 – . For assembly. reverse the disassembly procedure.

CARBURETOR

CARB

DISASSEMBLING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position.

CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber Cracks/damage → Replace.

2. Check: • fuel passages Obstruction → Clean.
wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww

a. Wash the carburetor in a petroleum based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air.
vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv

3. Check: • float chamber body Dirt → Clean. 4. Check: • float chamber rubber gasket 1 Cracks/damage/wear → Replace.

5. Check: • float Damage → Replace.

– 35 –

CARBURETOR

CARB

6. Check: • needle valve 1 • needle valve seat 2 Damage/obstruction/wear → Replace the needle valve, needle valve seat and O-ring as a set. 7. Check: • O-ring 3 Damage/wear → Replace the needle valve, needle valve seat and O-ring as a set. 8. Check: • piston valve 1 Damage/scratches/wear → Replace. • piston valve diaphragm 2 Cracks/tears → Replace.

9. • • • •

Check: vacuum chamber cover 1 piston valve spring 2 jet needle holder 3 jet needle spring 4 Cracks/damage → Replace.

10.Check: • jet needle kit 1 • main jet 2 • main jet holder 3 • pilot jet 4 • starter plunger 5 Bends/damage/wear → Replace. Obstruction → Clean. Blow out the jets with compressed air. 11.Check: • piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness → Replace the piston valve.

– 36 –

CARBURETOR

CARB

12.Check: • casting enricher 1 Cracks/tears → Replace. • casting enricher cover 2 • casting enricher spring 3 Cracks/damage → Replace. 13.Check: • fuel hoses Cracks/damage/wear → Replace. Obstruction → Clean. Blow out the hoses with compressed air. 14.Check: • hose joint Cracks/damage/wear → Replace. Obstruction → clean. Blow out to the joint with compressed air.

ASSEMBLING THE CARBURETOR

CAUTION:
• Before assembling the carburetors, wash all of the parts in a petroleum based solvent. • Always use a new gasket. NOTE: Before assembling the carburetor, make sure to turn out the pilot screw the same number of times, as noted before disassembly, from the seated position to the set position.

1. • • •

Install: needle valve 1 float 2 float pin 3

NOTE: Install the float pin from the side opposite the arrow.

– 37 –

f. Adjust: • throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv INSTALLING THE CARBURETOR 1. Measure the distance from the front mating surface of the float chamber (gasket removed) to the top of the float. inspect the valve seat and needle valve. Hold the carburetor in an upside down position.CARBURETOR CARB 2. Recheck the float height. d. NOTE: The float arm should be resting on the needle valve. c. 2. b.43 in) wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww a.39 ~ 0. replace them both. Float height (F. If the float height with not within the specification.350 ~ 1. Measure: • float height a Out of specification → Adjust.550 r/min Refer to “ADJUSTING IDLING SPEED”.H.20 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. If either is worn. adjust the float height by bending the float tang 1 on the float. e.12 ~ 0. THE ENGINE – 38 – .): 10 ~ 11 mm (0. but not compressing it. Adjust: • engine idling speed Engine idling speed 1. If both are fine.

Install the fuel level gauge 1 onto the fuel drain pipe 2. Install the carburetor assembly. Adjust: • fuel level wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww a. Stand the motorcycle on a level surface. Measure: • fuel level a Out of specification → Adjust. replace them as a set. Repeat steps (a) to (f) until the fuel level is within specification. Hold the fuel level gauge vertically next to the line 4 on the float chamber. Fuel level (above the line on the float chamber mating surface) 0. d. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv 2. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up.06 in) wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww a. Remove the carburetor assembly. Measure the fuel level again. If either is worn. Check the needle valve seat and needle valve. Measure the fuel level a. Loosen the fuel drain screw 3.5 ~ 1. f. e. e. g.5 mm (0.02 ~ 0. Fuel level gauge YM-01312-A d.CARBURETOR CARB MEASURING AND ADJUSTING THE FUEL LEVEL 1. c. adjust the float level by slightly bending the float tang 1. b. c. b. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv – 39 – . If both are fine. f.

R. disc NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. For installation. 6 LS LT LT Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. 9. Refer to “INSTALLING THE FRONT WHEEL”. 65 ft • Ib) T. – 40 – . (6) 13 Nm (1.FRONT WHEEL AND BRAKE DISC CHAS CHASSIS FRONT WHEEL AND BRAKE DISC 4 1 7 5 8 90 Nm (9.4 ft • Ib) T.0 m • kg. reverse the removal procedure.3 m • kg. 3 2 R. 1 2 3 4 5 6 7 8 Speedometer cable Axle nut Washer Front wheel axle Front wheel Speedometer gear unit Collar/dust seal Brake disc 1 1 1 1 1 1 1/1 1 Refer to “REMOVING AND INSTALLING THE FRONT WHEEL”.

FRONT WHEEL AND BRAKE DISC CHAS Order 1 2 3 Job/Part Disassembling the front wheel Oil seal Wheel bearing (left and right) Spacer Q’ty 1 2 1 Remarks Remove the parts in the order listed. – 41 – . reverse the disassembly procedure. For assembly.

FRONT WHEEL AND BRAKE DISC CHAS REMOVING THE FRONT WHEEL 1. – 42 – . • Loosen: axle nut: Elevate: front wheel NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. WARNING Securely support the motorcycle so that there is no danger of it falling over. • 3. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Stand the motorcycle on a level surface. 4. 2. • • • • Remove: axle nut washer front wheel axle front wheel NOTE: Do not squeeze the brake lever when removing the front wheel. CHECKING THE BRAKE DISC 1. Check: • brake disc Damage/galling → Replace.

14 in) Limit:3. Min.12 in) below the edge of the brake disc. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv 3. 9.FRONT WHEEL AND BRAKE DISC CHAS 2.3 m · kg. b. – 43 – . b. Max. Hold the dial gauge at a right angle against the brake disc surface. Measure the deflection 2 ~ 3 mm (0.12 in) 4. brake disc deflection 0. c. turn the handlebars to the left or right to ensure that the front wheel is stationary. Measure: • brake disc thickness Measure the brake disc thickness at a few different locations.5mm (0. Brake disc bolt 13 Nm (1.006 in) wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww a. brake disc thickness Standard:3. e. Out of specification → Replace.15 mm (0. Remove the brake disc. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. Remove the brake caliper.4 ft · lb) LOCTITE® T. R. d. Rotate the brake disc by one bolt hole. c. Place the motorcycle on a suitable stand so that the wheel is elevated. Adjust: • brake disc deflection wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww a. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Before measuring the front brake disc deflection.08 ~ 0. Install the brake disc.0 mm (0.

– 44 – .4 ft · lb) NOTE: • Apply locking agent (LOCTITE®) to the threads of the brake disc bolts. Lubricate: • wheel axle • oil seal lips Recommended lubricant Lithium soap base grease 2. 9. Install: • front wheel NOTE: Make sure the projection a (torque stopper) in the front fork is placed b in the speedometer gear unit as shown.FRONT WHEEL AND BRAKE DISC CHAS d. repeat the adjustment steps until the brake disc deflection is within specification. 4. • Tighten the brake disc bolts in stages and in a crisscross pattern. Install: • speedometer gear unit NOTE: Make sure the projections a in the wheel hub are meshed with the slots b in the speedometer gear unit. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv INSTALLING THE FRONT WHEEL 1. replace the brake disc. T.3 m · kg. Install: • brake discs 13 Nm (1. If the brake disc deflection cannot be brought within specification. 3. f. e. Measure the brake disc deflection. R. If out of specification.

65 ft · lb) T.FRONT WHEEL AND BRAKE DISC 5. – 45 – . CAUTION: Before tightening the wheel axle nut. R. push down hard on the handlebars several times and check if the front fork rebounds smoothly.0 m · kg. Tighten: • wheel axle nut 1 CHAS 90 Nm (9.

3 Order Job/Part Removing the front brake pads Retaining bolt (lower) Brake caliper Brake pad Brake pad spring Q’ty Remarks Remove the parts in the order listed. 1 2 3 4 1 1 2 2 For installation. 19 ft • Ib) 4 T. R. – 46 – .7 m • kg. reverse the removal procedure.FRONT BRAKE FRONT BRAKE FRONT BRAKE PADS CHAS LS 2 1 27 Nm (2.

• Brake fluid may damage painted surfaces and plastic parts. REPLACING THE FRONT BRAKE PADS 2 NOTE: When replacing the brake pads. the entire brake system must be disassembled. Remove: • retaining bolt (lower) 1 NOTE: Move the brake caliper 2 upward. 1. First aid for brake fluid entering the eyes: • Flush with water for 15 minutes and get immediate medical attention. Therefore. • If any connection on the hydraulic brake system is disconnected. cleaned. Therefore. drained. and bled after reassembly. it is not necessary to disconnect the brake hose or disassemble the brake caliper. • Use only clean or new brake fluid for cleaning brake components. always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. 1 – 47 – . always clean up any spilt brake fluid immediately. • Avoid brake fluid coming into contact with the eyes as it can cause serious injury. properly filled.FRONT BRAKE CAUTION: CHAS Disc brake components rarely require disassembly. • Never use solvents on internal brake components.

Put the other end of the hose into an open container. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv T.03 in) 4.FRONT BRAKE 2. Bleed screw 6 Nm (0. Tighten the bleed screw. Remove: • brake pads 1 • brake pad springs CHAS 1 3. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. Connect a clear plastic hose 1 tightly to the bleed screw 2. Brake pad wear limit 0. Install new brake pad springs and a new brake pads. c. 4.8 mm (0. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Install: • brake pad springs • brake pads NOTE: Always install new brake pads and a brake pad springs as a set. b. wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww 1 2 a. – 48 – . R.3 ft · lb) d.6 m · kg.

T.FRONT BRAKE 5.7 m · kg. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. – 49 – . R. 7. Refer to “CHECKING THE BRAKE FLUID LEVEL”. Install: • retaining bolt (lower) CHAS 27 Nm (2. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. 19 ft · lb) 6.

8 7 LS 1 9 New 5 2 LS 3 6 4 30 Nm (3.FRONT BRAKE FRONT BRAKE MASTER CYLINDER CHAS 7 Nm (0.0 m • kg. 22 ft • Ib) T. – 50 – . R. reverse the removal procedure. Drain. 5. R.1 ft • Ib) T.7 m • kg. Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the front brake master cylinder Brake fluid Rear view mirror (right) Brake lever/spring Front brake light switch Union bolt Copper washer Brake hose Brake master cylinder holder Brake master cylinder reservoir cap Brake master cylinder assembly Q’ty Remarks Remove the parts in the order listed. 1 1/1 1 1 2 1 1 1 1 For installation.

reverse the disassembly procedure.FRONT BRAKE CHAS 2 New 3 1 4 5 Order 1 2 3 4 5 Job/Part Disassembling the front brake master cylinder Brake master cylinder reservoir diaphragm Dust boot Circlip Brake master cylinder kit Brake master cylinder Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 1 For assembly. – 51 – .

1. Check: • brake master cylinder kit Damage/scratches/wear → Replace. • brake master cylinder reservoir diaphragm 2 Damage/were → Replace. place a container under the master cylinder and the end of the brake hose. 2. Check: • brake master cylinder reservoir 1 Cracks/damage → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. 1 – 52 – . 2 3. drain the brake fluid from the entire brake system. Check: • brake master cylinder 1 Damage/scratches/wear → Replace.FRONT BRAKE CHAS DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder. • • • Remove: union bolt 1 copper washers 2 brake hose 3 1 2 2 3 NOTE: To collect any remaining brake fluid. Disconnect • front brake light switch 2. 1 CHECKING THE FRONT BRAKE MASTER CYLINDER 1.

T. • • • Install: copper washers New brake hose 30 Nm (3. R. tighten the upper bolt. 2.g.1 ft · lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. Install: • brake master cylinder 1 7 Nm (0. – 53 – .FRONT BRAKE CHAS ASSEMBLING AND INSTALLING THE FRONT BRAKE MATER CYLINDER WARNING • Before installation. tighten the union bolt as shown. then the lower bolt.4 m · kg. • Turn the handlebars to the left and to the right to make sure that the brake hose does not touch other parts (e. Recommended brake fluid DOT 4 1. Refer to “CABLE ROUTING”. • First.wire harness. cables. • Align the end of the brake master cylinder holder with the punch mark a in the right handlebar.0 m · kg.. NOTE: • While holding the brake hose. Correct if necessary. leads). all internal brake components should be cleaned and lubricated with clean or new brake fluid. 5. • Never use solvents on internal brake components. 22 ft · lb) union bolt T. R. WARNING 45°±10 Proper brake hose routing is essential to insure safe motorcycle operation.

FRONT BRAKE CHAS 3. leading to poor brake performance. • When refilling. always clean up any spilt brake fluid immediately. 4. Other brake fluids may cause the rubber seals to deteriorate. CAUTION: Brake fluid may damage painted surfaces and plastic parts. • Refill with the same type of brake fluid that is already in the system. Check: • brake fluid level Below the minimum level mark a → 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. Mixing brake fluids may result in a harmful chemical reaction. be careful that water does not enter the brake fluid reservoir. – 54 – . Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Fill: • brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL”. 6. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. 5. causing leakage and poor brake performance. Therefore.

0 m • kg. 5 LS 4 30 Nm (3. 22 ft • Ib) T. Order R. 4 T. 27 Nm (2.FRONT BRAKE FRONT BRAKE CALIPER CHAS 2 New 3 1 30 Nm (3.0 m • kg. 22 ft • Ib) T. Q’ty Remarks Remove the parts in the order listed. For installation. R. Drain. 19 ft • Ib) 1 2 3 4 5 Job/Part Removing the front brake calipers Brake fluid Union bolt Copper washer Brake hose Retaining bolt Brake caliper R. 1 2 1 2 1 Loosen. reverse the removal procedure. – 55 – .7 m • kg.

pers Retaining bolt 2 Brake caliper bracket 1 Brake pad 2 Brake pad spring 2 Brake caliper piston 2 Brake caliper piston seal 4 Bleed screw 1 For assembly.FRONT BRAKE CHAS Order 1 2 3 4 5 6 7 Job/Part Q’ty Remarks Disassembling the front brake caliRemove the parts in the order listed. reverse the disassembly procedure. – 56 – .

WARNING • Cover the brake caliper pistons with a rag. 2. drain the brake fluid from the entire brake system. vvvvvvvvvvvvvvvvvvvvvvvvvvvvvvvv – 57 – . 3 1 2 1. • Never try to pry out the brake caliper pistons.FRONT BRAKE CHAS DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling either brake caliper. Remove: • brake caliper pistons 1 • brake caliper piston seals 2 wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww a. b. Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper. Remove the brake caliper piston seals. Be careful not to get injured when the pistons are expelled from the brake caliper. • • • Remove: union bolt 1 copper washers 2 brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

2. WARNING Whenever a brake caliper is disassembled. • brake caliper cylinders 2 Scratches/wear → Replace the brake caliper. – 58 – . Check: • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper.FRONT BRAKE CHAS CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads Piston seals Brake hoses If necessary Every two years Every four years Every two years and whenever the brake is disassembled Brake fluid 2 2 1 1. Check: • brake caliper bracket 1 Cracks/damage → Replace. • brake calipers Cracks/damage → Replace. replace the brake caliper piston seals. • brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air.

R. make sure that the brake pipe a touches the projection b on the brake caliper. Refer to “CABLE ROUTING”. 22 ft · lb) union bolt 2 T. CAUTION: When installing the brake hose onto the brake caliper. • brake caliper 2 NOTE: Temporarily tighten the retaining bolts.0 m · kg. Install: • brake caliper bracket 1 30 Nm (3. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. R. – 59 – . all internal brake components should be cleaned and lubricated with clean or new brake fluid. replace the brake caliper piston seals.0 m · kg.FRONT BRAKE CHAS ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS WARNING • Before installation. 22 ft · lb) T. • Whenever a brake caliper is disassembled. 1 2 WARNING Proper brake hose routing is essential to insure safe motorcycle operation. • • • Install: copper washers New brake hose 1 30 Nm (3. 1 2. Recommended brake fluid DOT 4 2 1.

Other brake fluids may cause the rubber seals to deteriorate. 5. • When refilling. – 60 – . leading to poor brake performance.Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. be careful that water does not enter the brake fluid reservoir. • 4. R. 6.FRONT BRAKE 3. • Refill with the same type of brake fluid that is already in the system. • • • CHAS Remove: retaining bolt (lower) Install: brake pad springs brake pads 27 Nm (2. 19 ft · lb) brake caliper T. CAUTION: Brake fluid may damage painted surfaces and plastic parts. causing leakage and poor brake performance. Mixing brake fluids may result in a harmful chemical reaction. always clean up any spilt brake fluid immediately.Therefore.7 m · kg. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Fill: • Brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT4 WARNING • Use only the designated brake fluid.

Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. – 61 – . Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system.FRONT BRAKE CHAS 7. Refer to “CHECKING THE BRAKE FLUID LEVEL”. 8.

Order Job/Part Removing the front fork legs Q’ty Front wheel 1 2 3 4 5 6 7 Brake hose holder Cable guide Front fender Upper bracket pinch bolt Cap bolt Lower bracket pinch bolt Front fork leg 1 1 1 1 1 2 1 Remarks Remove the parts in the order listed. Loosen. R. 1 30 Nm (3. The following procedure applies to both of the front fork legs. Refer to “FRONT WHEEL AND BRAKE DISCS”. R. 17 ft • Ib) T.FRONT FORK FRONT FORK CHAS 23 Nm (2. 4 6 3 7 7 2 23 Nm (2. For installation reverse the removal procedure. T. Loosen. 22 ft • Ib) T.3 m • kg.3 m • kg. 17 ft • Ib) 23 Nm (2. – 62 – . Loosen. R.3 m • kg. 5 R.0 m • kg. 17 ft • Ib) (4) T.

27 ft • lb) 2nd 18 Nm (1. Front fork legs Headlight stay assembly/meter assembly Main switch coupler 1 Disconnect. 3 T. R. Steering stem bolt 1 Upper bracket 1 Ring nut 1 Lower bracket 1 Bearing cover 1 Bearing inner race 1 Upper bearing 1 Lower bearing 1 Bearing inner race 1 Rubber washer 1 – 63 – . 1 4 LS LS 9 10 11 12 6 7 8 5 LS 13 Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed.0 m • kg. 65 ft • Ib) 2 1st 38 Nm (3. R.8 m • kg.8 m • kg.STEERING HEAD STEERING HEAD CHAS 90 Nm (9. 13 ft • lb) T.

8 m • kg. 1 4 LS LS 9 10 11 12 6 7 8 5 LS 13 Order 12 13 Job/Part Bearing outer race Bearing outer rase Q’ty 1 1 Remarks For installation reverse the removal procedure. – 64 – . 3 T. 27 ft • lb) 2nd 18 Nm (1.8 m • kg. 65 ft • Ib) 2 1st 38 Nm (3. R. 13 ft • lb) T. R.0 m • kg.STEERING HEAD CHAS 90 Nm (9.

• Since there are differences in both the upper and lower bearings. the bearings can be identified by the projection on the surface of the retainer. Install: • Bearing (retainer type) NOTE: • When install the bearing (retainer type) make sure that the projections 1 on the surface of the bearing face upward. É 1 È Upper É Lower – 65 – .STEERING HEAD È CHAS 1 INSTALLING THE BEARING (RETAINER TYPE) 1.

ELECTRICAL COMPONENTS ELEC – + ELECTRICAL ELECTRICAL COMPONENTS 1 Wire harness 2 Main switch 3 Front brake light switch 4 Main fuse 5 Starter relay 6 Neutral relay 7 Diode 8 CDI unit 9 Clutch switch 0 Battery A Rectifier/regulator B Turn signal relay C Sidestand switch D Neutral switch E Pickup coil F Stator coil assembly G Rear brake light switch H Horn I Ignition coil – 66 – .

check the wiring connections and if necessary. a closed circuit at the respective switch position).. If the continuity reading is incorrect. and between blue/yellow and blue/black when the switch is set to “ON”. CAUTION: Never insert the tester probes into the coupler terminal slots 1. taking care not to loosen or damage the leads.e. • When checking for continuity. Always insert the probes from the opposite end of the coupler. set the pocket tester to “0” and to the “Ω × 1” range. replace the switch. NOTE: “ ” indicates a continuity of electricity between switch terminals (i.g. Pocket tester YU-03112 NOTE: • Before checking for continuity.. 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.SWITCHES SWITCHES “∞” “0” ELEC – + “Ω×1” CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. engine stop switch) are shown in an illustration similar to the one on the left. The terminal connections for switches (e. switch back and forth between the switch positions a few times. The example illustration on the left shows that: There is continuity between red and brown/ blue. 1 R Br/L L/Y L/B ON OFF R Br/L L/Y L/B – 67 – .main switch.

proper connections. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace the switch. 1 P FREE PUSH 2 B L NL OFF NR R 3 Dg Br/W Ch LO HI G Br Y Br/W Ch P B Dg L/B (BLACK) Y 6 L/W B 7 R/W R/W OFF RUN ON 4 R Br/L L/Y L/B OFF ON OFF R Br/L L/Y L/B (RED) R/W R/W L/W B 5 B B 8 B B (BLACK) 9 B B 0 Sb A B B B (BLUE) – 68 – . and also for continuity between the terminals.CHECKING THE SWITCHES CHECKING THE SWITCHES ELEC – + Check each switch for damage or wear.

CHECKING THE SWITCHES 1 Horn switch 2 Turn signal switch 3 Dimmer switch 4 Main switch 5 Clutch switch 6 Start switch 7 Engine stop switch 8 Front brake light switch 9 Rear brake light switch 0 Fuse A Neutral switch B Sidestand switch ELEC – + – 69 – .

R W W/L W/R O B W/R W/L B/R L/Y G/W W W W W Br G G/W B/R W W/R W/L O O W (GRAY) (GRAY) 1 B/R G/W W/R W/L G B B/R G/W Sb F H Sb R R R B L/Y Br R/W (BLACK) L/Y W W W Sb 2 5 R Br R R/W (RED) R/W L/W (RED) R B R CIRCUIT DIAGRAM A OFF ON 6 8 L/W OFF RUN B R/W R/W B L/W L/W L/B L/W R Br/L L/Y L/B Br R L/B L/Y W W W IGNITION SYSTEM 4 9 0 Br L/B L/B OFF ON B/W B L/W R/W R/W R/W L/W B B B B R B 3 7 C L/W L/B L/B B B B B B B B B/W W W R W L/B L/W Br D (BLUE) Sb B/W (BLUE) B/W B B L/B B/W E Br L/W Sb B/W I L – 70 – Br Br J Sb Br Br Br/W Y K L Br Sb B Br/W Br Sb Br B Dg Ch W (BLACK) Br/W Br/W Br X B B P S P Br/W Br Br Br T FREE PUSH OFF NR R NL L IGNITION SYSTEM U V LO HI Ch Br/W B P Br Dg Br/W Ch P B Dg L/B (BLACK) (BLACK) Br G/Y Y B B (BLACK) (BLACK) N G/Y M B Dg Ch G Y G/Y Dg Dg L Ch Ch G Y ELEC Y L Q R B RQ P Y G B O – 1 AC magneto 0 Engine stop switch A Main switch D Sidestand switch F CDI unit G Ignition coil H Spark plug B B B B B B + .

pickup coil resistance 6. spark plug cap resistance 4. source coil resistance 7.IGNITION SYSTEM TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). remove the following part (-s): 1) rider seat 2) fuel tank 3) side cover (left and right) • Troubleshoot with the following special tool (-s). engine stop switch 9. sidestand switch 10. ignition spark gap 3. • Measure the spark plug gap. Spark plug ELEC – + The following procedure applies to all of the spark plug. • Check the condition of the spark plug. is it of the correct type. Dynamic spark tester YM-34487 Pocket tester YU-03112 1. Check: 1.024 ~ 0.6 ~ 0.wiring (of the entire ignition system) NOTE: • Before troubleshooting.7 mm (0. • Check the spark plug type. Standard spark plug DR8EA (NGK) X24ESR-U (DENSO) Spark plug gap 0.028 in) • Is the spark plug in good condition. – 71 – . spark plug 2. ignition coil resistance 5. main switch 8. and its gap within specification? YES NO Re-gap or replace the spark plug.

Measure the ignition spark gap a.24 in) • Is there a spark and is the spark gap within specification? NO YES The ignition system is OK. Connect the dynamic spark tester 1 as shown. • Disconnect the spark plug cap from the spark plug. • • • • • • Spark plug cap resistance 10 kΩ at 20 °C (68 °F) • Is the spark plug cap OK? YES Min. 2 Spark plug cap Set the main switch to “ON”. Replace the plug cap. Spark plug cap resistance The following procedure applies to all of the spark plug cap.IGNITION SYSTEM 2. • Connect the pocket tester(Ω × 1k) to the spark plug cap as shown. • Measure the spark plug cap resistance. Disconnect the spark plug cap from the spark plug. Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs. Ignition spark gap The following procedure applies to all of the spark plug. NO spark – 72 – . ELEC – + 3.ignition spark gap 6 mm (0.

18 ~ 0. Tester positive probe → orange Tester positive probe → spark plug lead • Measure the pickup coil resistance. Primary coil resistance 0.32 ~ 9. Tester positive probe → white 1 Tester negative probe → red 2 • Measure the primary coil resistance. – 73 – .IGNITION SYSTEM 4.28 Ω at 20 °C (68 °F) • Connect the pocket tester (Ω × 1k) to the ignition coil as shown. Pickup coil resistance ELEC – + • Disconnect the pickup coil coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the pickup coil terminal as shown. • Measure the secondary coil resistance. Secondary coil resistance 6. Pickup coil resistance 656 ~ 984 Ω at 20 °C (68 °F) (between white and red) • Is the pickup coil OK? YES NO Replace the pickup coil. • Connect the pocket tester (Ω × 1) to the ignition coil as shown. Tester Positive → orange Tester negative → ignition coil base 5. Ignition coil resistance • Disconnect the ignition coil connector from the ignition coil terminal.48 kΩ at 20 °C (68 °F) • Is the ignition coil OK? YES NO Replace the ignition coil.

• Connect the pocket tester (Ω × 100) to the source terminal as shown. Engine stop switch ELEC – + • Check the engine stop switch for continuity. EB802411 NO Replace the stand switch. Source coil resistance 624 ~ 936 Ω at 20 °C (68 °F) (between green and brown) • Is the source coil OK? YES NO Replace the source coil assembly. • Is the sidestand switch OK? YES • Measure the source coil resistance. Refer to “CHECKING THE SWITCHES”. EB802414 9. Refer to “CHECKING THE SWITCHES” • Is the engine stop switch OK? YES NO Replace the right handlebar switch. • Is the ignition system’s wiring properly connected and without defects? NO YES Replace the CDI unit. Sidestand switch • Check the sidestand switch for continuity. Refer to “CIRCUIT DIAGRAM”. – 74 – .IGNITION SYSTEM 6. side- EB802416 10. • Is the main switch OK? YES Replace switch. Refer to “CHECKING THE SWITCHES”. Main switch • Check the main switch for continuity. NO the main Properly connect or repair the ignition system’s wiring. Source coil resistance • Disconnect the source coil coupler from the wire harness. 7.Wiring • Check the entire ignition system’s wiring. Tester positive prove → green 1 Tester negative prove → brown 2 8.

R W W/L W/R O B W/R W/L B/R L/Y G/W W W W W Br G G/W B/R W W/R W/L O O W (GRAY) (GRAY) 1 B/R G/W W/R W/L G B B/R G/W Sb F H Sb R R R B L/Y Br R/W (BLACK) L/Y W W W Sb 2 5 R Br R R/W (RED) R/W L/W (RED) R B R CIRCUIT DIAGRAM A OFF ON 6 8 L/W OFF RUN B R/W R/W B L/W L/W L/B L/W R Br/L L/Y L/B Br R L/B L/Y W W W 4 9 0 Br L/B L/B OFF ON B/W B L/W R/W R/W R/W L/W B B B B R B 3 7 C L/W L/B L/B B B B B B B B B/W W W R W L/B L/W Br ELECTRIC STARTING SYSTEM D (BLUE) Sb B/W (BLUE) B/W B B L/B B/W E Br L/W Sb B/W I L ELECTRIC STARTING SYSTEM – 75 – Br Br J Sb Br Br Br/W Y K L Br Sb B Br/W Br Sb Br B Dg Ch W (BLACK) Br/W Br/W Br X B B P S P Br/W Br Br Br T FREE PUSH OFF NR R NL L U V LO HI Ch Br/W B P Br Dg Br/W Ch P B Dg L/B (BLACK) (BLACK) Br G/Y Y B B (BLACK) (BLACK) N G/Y M B Dg Ch G Y G/Y Dg Dg L Ch Ch G Y ELEC Y L Q R B RQ P Y G B O – 2 Neutral switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 9 Start switch 0 Engine stop switch A Main switch B Diode C Clutch switch D Sidestand switch E Neutral relay B B B B B B + .

the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch is closed). WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Starter motor 2 Battery 3 Starter relay 4 Main fuse 5 Main switch 6 Start switch 7 Diode 8 Clutch switch 9 Sidestand switch 0 Neutral relay A Engine stop switch B Neutral switch – 76 – .ELECTRIC STARTING SYSTEM ELEC – + 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). • The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).

Specific gravity 1.ELECTRIC STARTING SYSTEM TROUBLESHOOTING The starter motor fails to turn.wiring (of the entire starting system) NOTE: • Before troubleshooting. remove the following part(-s): 1) rider seat 2) fuel tank 3) side cover (left and right) • Troubleshoot with the following special tool(-s). Starter motor • Connect the battery positive terminal 1 and starter motor lead 2 with a jumper lead 3. engine stop switch 9. • Does the starter motor turn? YES NO Repair or replace the starter motor. • Recharge or replace the battery. diode 6. • Clean the battery terminals.sidestand switch 11.280 at 20 °C (68 °F) • Is the battery OK? YES NO • Refill battery fluid. Main fuse • Check the main fuse for continuity.start switch 13. main fuse 2. 1. • Are the main fuse OK? YES NO Replace the fuse. neutral relay 5. starter motor 4. therefore make sure that no flammable gas or fluid is in the vicinity. battery 3. – 77 – .clutch switch 12. • This check is likely to produce sparks. WARNING • A wire that is used as a jumper lead must have at least the same capacity of the battery lead. main switch 8. Pocket tester YU-03112 EB802400 ELEC – + 2. Battery • Check the battery fluid level. otherwise the jumper lead may burn. EB803400 3. neutral switch 10. starter relay 7. battery terminal and specific gravity. Check: 1.

• Check the diode for continuity. – 78 – . Tester positive probe → blue/white 1 ContinuTester negative probe → ity blue/black 2 Tester positive probe → blue/black 2 No contiTester negative probe → nuity blue/white 1 • Does the neutral relay have continuity between blue/white and black/white? YES NO Replace the Neutral relay. • Connect the pocket tester (Ω × 1) to the diode terminals as shown. • Check the neutral relay for continuity. Diode ELEC – + • Remove the diode from the wire harness.ELECTRIC STARTING SYSTEM 4. Neutral relay • Remove the neutral relay from the wire harness. Battery positive terminal → brown 1 Battery negative terminal → sky blue 2 Tester positive probe → blue/white 3 Tester negative probe → black/white 4 5. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the neutral relay terminals. • Is the diode OK? YES NO Replace the diode.

Battery positive terminal → brown 1 Battery negative terminal → red/white 2 Tester positive probe → red 3 Tester negative probe → black 4 EB802413 ELEC – + 8.Sidestand switch • Check the sidestand switch for continuity. Neutral switch • Check the neutral switch for continuity. 9. • Is the sidestand switch OK? YES NO Replace the stand switch. EB802411 10. • Is the neutral switch OK? YES NO Replace the neutral switch. • Is the clutch switch OK? YES NO Replace the clutch switch. Main switch • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Refer to “CHECKING THE SWITCHES”. NO the main 11. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the starter relay coupler as shown. EB803405 side- 7. – 79 – .ELECTRIC STARTING SYSTEM 6. Starter relay • Remove the starter relay from the wire harness. Refer to “CHECKING THE SWITCHES”. Engine stop switch • Check the engine stop switch for continuity. • Is the main switch OK? YES Replace switch. Refer to “CHECKING THE SWITCHES”.Clutch switch • Check the clutch switch for continuity. EB802414 • Does the starter relay have continuity between red and black? YES NO Replace the starter relay. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? YES NO Replace the right handlebar switch. • Check the starter relay for continuity.

Wiring • Check the entire starting system’s wiring. EB803408 ELEC – + 13.ELECTRIC STARTING SYSTEM 12. • Is the starting system’s wiring properly connected and without defects? NO Properly connect or repair the starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? YES NO Replace the right handlebar switch.Start switch • Check the start switch for continuity. YES The starting system circuit is OK. – 80 – .

R

W

W/L W/R

O B W/R W/L B/R L/Y G/W

W W

W W

Br

G

G/W B/R

W W/R W/L O O

W

(GRAY)

(GRAY)

1
B/R G/W

W/R W/L

G
B

B/R

G/W Sb

F H

Sb R R R B L/Y Br R/W (BLACK)

L/Y

W W W

Sb

2 5
R Br R R/W (RED) R/W L/W (RED) R B R

CIRCUIT DIAGRAM

A
OFF ON

6 8
L/W OFF RUN B R/W R/W B L/W L/W L/B L/W

R Br/L L/Y L/B Br R L/B L/Y

W W W

4 9 0
Br L/B L/B OFF ON B/W B L/W R/W R/W R/W L/W B B B

B

R B

SIGNALING SYSTEM

3 7 C
L/W L/B L/B B B

B

B

B

B B B/W

W

W

R

W

L/B L/W

Br

D
(BLUE) Sb B/W (BLUE) B/W

B B

L/B B/W

E
Br L/W

Sb B/W

I
L

– 81 –
Br Br

J
Sb Br Br Br/W Y

K L
Br Sb B Br/W Br Sb Br B Dg Ch

W
(BLACK) Br/W

Br/W Br

X

B B

P

S
P Br/W

Br Br Br

T
FREE PUSH OFF NR R NL L

SIGNALING SYSTEM

U

V
LO HI

Ch Br/W B P Br Dg Br/W Ch P B Dg L/B (BLACK) (BLACK)

Br G/Y Y

B B (BLACK) (BLACK)

N
G/Y

M

B

Dg

Ch G Y

G/Y

Dg

Dg

L

Ch

Ch

G Y

ELEC

Y L

Q

R

B

RQ

P
Y

G B

O

2 Neutral switch 4 Battery 5 Main fuse A Main switch J Neutral indicator light K Turn signal indicator light M Rear brake light switch N Front brake light switch O Tail/brake light Q Rear turn signal light R Front turn signal/position light T Horn switch U Turn signal switch W Horn X Turn signal relay
B B B B B

B

+

SIGNALING SYSTEM
TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. Check: 1. main fuse 2. battery 3. main switch 4. wiring (of the entire signaling system) NOTE: • Before troubleshooting, remove the following part(-s): 1) seats 2) fuel tank 3) side cover (left and right) 4) headlight cover 5) rear fender • Troubleshoot with the following special tool (-s). Pocket tester YU-03112
EB802400

ELEC

+

2. Battery • Check the battery fluid level, battery terminal and specific gravity. Specific gravity 1.280 at 20 °C (68 °F) • Is the battery OK? YES NO • Refill battery fluid. • Clean the battery terminals. • Recharge or replace the battery.
EB802411

3. Main switch • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? YES Replace switch.
EB806400

NO the main

1. Main fuse • Check the main fuse for continuity. • Are the main system fuse OK? YES NO Replace the fuse. 4. Wiring

• Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the signaling system’s wiring properly connected and without defects? YES Check the condition of each of the signaling system’s circuits. Refer to “CHECKING THE SIGNALING SYSTEM”. NO Properly connect or repair the signaling system’s wiring.

– 82 –

SIGNALING SYSTEM
CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. 1. Horn switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? YES NO Replace the left handlebar switch. 2. Voltage • Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown. Tester positive probe → brown 1 Tester negative probe → ground NO 3. Horn

ELEC

+

• Disconnect the pink connector at the horn terminal. • Connect a jumper lead 1 to the horn terminal and ground the jumper lead. • Set the main switch to “ON”. • Push the horn switch. • Does the horn sound?

YES The horn is OK.

4. Voltage • Connect the pocket tester (DC 20 V) to the horn connector at the pink terminal as shown. Tester positive probe → pink 1 Tester negative probe → ground

• Set the main switch to “ON”. • Push the horn switch. • Measure the voltage (12 V) of brown at the horn terminal. • Is the voltage within specification? YES NO The wiring circuit from the main switch to the horn connectors is faulty and must be repaired.

• Set the main switch to “ON”. • Measure the voltage (12 V) of pink 1 at the horn terminal. • Is the voltage within specification? YES Repair or replace the horn. NO Replace the horn.

– 83 –

• Pull in the brake lever or push down on the brake pedal. 3.SIGNALING SYSTEM 2. 1. Brake light switches • Check the brake light switches for continuity. NO The wiring circuit from the main switch to the tail/brake light connectors is faulty and must be repaired. • Are the turn signal light bulb and socket OK? YES NO Replace the turn signal light bulb. • Are the tail/brake light bulb and socket OK? YES NO Replace the tail/ brake light bulb. – 84 – . 1. turn signal indicator light or both fail to blink. • Measure the voltage (12 V) of yellow at the tail/brake light connector (wire harness side). Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. 2. • Is the voltage within specification? YES This circuit is OK. A turn signal light. Refer to “CHECKING THE SWITCHES”. 3. Tester positive probe → yellow 1 Tester negative probe → black 2 • Set the main switch to “ON”. socket or both. A tail/brake light fails to come on. Turn signal light bulb and socket • Check the turn signal sight bulb and socket for continuity. • Is the brake light switch OK? YES NO Replace the brake light switch. Voltage ELEC – + • Connect the pocket tester (DC 20 V) to the tail/brake light connectors (wire harness side) as shown. socket or both.

3. • Measure the voltage (12 V) of brown 1 at the turn signal relay coupler (wire harness side). Turn signal switch • Check the turn signal switch for continuity. • Is the turn signal switch OK? YES NO Replace the left handlebar switch. • Is the voltage within specification? YES NO The wiring circuit from the main switch to the turn signal relay coupler (turn signal relay side) is faulty and must be repaired. Tester positive probe → brown 1 Tester negative probe → ground • Set the main switch to “ON”. 4. Voltage ELEC – + • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.SIGNALING SYSTEM 2. – 85 – . • Are the turn signal indicator light bulb and socket OK? YES NO Replace the meter assembly. Turn signal indicator light bulb and socket • Check the turn signal indicator light bulb and socket for continuity. Refer to “CHECKING THE SWITCHES”.

• Set the turn signal switch to “ ”or “ ”. Voltage ELEC – + • Connect the pocket tester (DC 20 V) to the turn signal light connectors or the meter assembly coupler (wire harness side) as shown. • Measure the voltage (12 V) of brown/white 1 at the turn signal relay coupler (wire harness side). Tester positive probe → brown/white 1 Tester negative probe → ground 6. NO The wiring circuit from the turn signal switch to the turn signal light connectors is faulty and must be repaired. Voltage • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.SIGNALING SYSTEM 5. Left turn signal light Tester positive probe → chocolate 1 Tester negative probe → ground Right turn signal light Tester positive probe → dark green 2 Tester negative probe → ground Turn indicator light Tester positive probe → brown 3 Tester negative probe → ground È É • Set the main witch to “ON”. • Is the voltage within specification? YES NO The turn signal relay is faulty and must be replaced. • Is the voltage within specification? YES This circuit is OK. • Set the turn signal switch to “ ” or “ ”. È Turn signal light É Turn signal indicator light • Set the main switch to “ON”. – 86 – . • Measure the voltage (12 V) of chocolate 1 or dark green 2 at the turn signal light connectors wire harness side).

3. • Is the voltage within specification? YES NO – 87 – . 1. The neutral indicator light fails to come on. • Measure the voltage (12 V) of brown 1 and sky blue 2 at the meter assembly coupler. Refer to “CHECKING THE SWITCHES”. Neutral switch • Check the neutral switch for continuity. The wiring circuit from the main switch to the meter light bulb coupler is faulty and must be repaired. • Is the neutral switch OK? YES NO Replace the neutral switch. • Set the main switch to “ON”. Neutral indicator light bulb and socket • Check the neutral indicator light bulb and socket for continuity. This circuit is OK. • Are the neutral indicator light bulb and socket OK? YES NO Replace the meter assembly. Voltage ELEC – + • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Tester positive probe → brown 1 Tester negative probe → sky blue 2 2.SIGNALING SYSTEM 4.

YAMAHA MOTOR CO.. LTD.S. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.A. .

pink R...........black/red B/W...... red Sb.........brown/white G/W .......TW200EN/TW200ENC WIRING DIAGRAM R Br W G W/L W/R O B W/R W/L B/R L/Y G/W W W W W W W G/W B/R (GRAY) W/R W/L B/R G/W Sb W/R W/L B/R G/W L/Y O O B (GRAY) 1 Sb W W W Sb F G H 2 R R R R R Br R/W (BLACK) Br R/W R/W 5 6 B R L/Y B A OFF ON R Br/L L/Y L/B (RED) Br R L/B L/Y (RED) L/W W W W R 4 B R B 8 B/W B L/W R/W 9 OFF ON R/W R/W L/W B L/W 0 OFF RUN B R/W R/W B L/W Br L/B L/B B L/B 3 L/W B B B B 7 L/W B W R W W B B/W C L/B B B L/W L/B L/B Br L/W D B/W B B (BLUE) L/B B/W (BLUE) E Sb B/W Sb B/W Br L/W I L J Sb Br Br Br/W Br Br Y K L Sb Br B Dg Ch 1 AC magneto 2 Neutral switch 3 Rectifier/regulator 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Right handlebar switch 9 Start switch 0 Engine stop switch A Main switch B Diode C Clutch switch D Sidestand switch E Neutral relay F CDI unit G Ignition coil H Spark plug I Meter light J Neutral indicator light K Turn signal indicator light L High beam indicator light M Rear brake light switch N Front brake light switch O Tail/brake light P Headlight Q Rear turn signal light R Front turn signal/position light S Left handlebar switch T Horn switch U Turn signal switch V Dimmer switch W Horn X Turn signal relay W Br/W Br (BLACK) X Br/W Br Sb B Br/W Br B B P S T FREE PUSH P Br/W Br U L NL OFF NR R V LO HI Br Br Ch Br/W B P Br Dg (BLACK) Br/W Ch P B Dg L/B (BLACK) Br G/Y Y B B N G/Y M (BLACK) (BLACK) B Dg Ch G Y G/Y Dg Dg L Ch Ch G Y Y L Q R B RQ P G Y B O B B B B B B COLOR CODE B ........... red/blue R/W ....blue O ......... orange P...green L.green/white G/Y ........green/yellow L/B ................................. sky blue W....................brake/white Br/W...........................chocolate Dg .. yellow B/R......... white/blue W/R ....... red/white W/L . blue/white L/Y ...dark green G ..... white/red ..........black Br ..brown Ch ................. blue/yellow R/L . white Y..........blue/black L/W .............

Sign up to vote on this title
UsefulNot useful