vx 250 repair manual

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.YAMAHA 302 motorcycle 250 LlT-11616-XV-25

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Repair manual for Yamaha VX250 Route 66

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.YAMAHA 302motorcycle 250 LlT-11616-XV-25 YAMAHA LlT116160969 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the XV250G/XV250GC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. XV250U/XV250UC SERVICE MANUAL: 2UJ-28197-10 XV250G/XV250GC SUPPLEMENTARY SERVICE MANUAL 1994 by Yamaha Motor Co., Ltd. 1st Edition, September 1994 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. NOTICE This manual was written by Yamaha Motor Company Ltd. primarily for use by Yamaha dealers andqualifiedmechanics.Itisnotpossibletoputanentiremechanic'seducationintoone manual, sopersons using this book to performmaintenance andrepairs onYamahamotor-cycles should have a basic understanding ofthe mechanical concepts and procedures inherent inmotorcycle repair technology. Without such knowledge, attempted repairs or service to the motorcycle may render it unfit to use and/or unsafe. For USA, California This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools in necessary to ensure that themotorcycle will operateasdesigned.If thereisany question about a serviceprocedure,itisimperativethatyoucontactaYamahadealerforanyservice informationchangesthatapplytothismodel.Thispolicyisintendedtoprovidethe customer withthemostsatisfactionfromhismotorcycleandtoconformwithfederal environmental quality objectives. YamahaMotor Company,Ltd.is continually striving to improve allmodels manufactured by Yamaha.Modificationsandsignificantchangesinspecificationsorprocedureswillbefor-warded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. NOTE: FORUSA, California: ThisServiceManualcontainsinformationregardingperiodicmaintenancetotheemission control system. Pleasereadthis material carefully. PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. AWARNING NOTE: TheSafety Alert Symbolmeans ATTENTION!BECOMEALERT!YOUR SAFETY ISINVOLVED! Failure to follow WARNINGinstructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle. ACAUTIONindicatesspecialprecautionsthatmust be takento avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer. HOW TO USE THIS MANUAL CONSTRUCTION OF THISMANUAL This manual consists of chapters forthe main categories of subject. (See "Illustrated symbols") 1 title CD: 2nd title : This is a chapter with its symbol on the upper right of eachpage. This titleappearsontheupper of eachpageontheleft of the chapter symbol. (For the chapter "Periodic inspection andadjustment" the 3rd title appears.) 3rd@:This is a final title. MANUAL FORMAT Allof theproceduresinthismanualareorganizedinasequential,step-by-step format.The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensiveexplanations of alldisassembly,repair,assembly,andinspec-tions. A set of particularly important procedure @ is placed between a line of asterisks" *" with eachprocedure preceded by "e". IMPORTANT FEATURES Dataand a special tool are framed in a box preceded by a relevant symbol . An encircled numeral indicates a part name, and an encircled alphabetical letter data or an alignment mark (j),the others beingindicated by analphabeticalletter ina box @. Aconditionof a faulty component willprecedeanarrow symbol andthe course of action required the symbol @. EXPLODED DIAGRAM Eachchapterprovidesexplodeddiagramsbeforeeachdisassemblysectionforeasein identifying correct disassembly and assembly procedures.

_______'RO_NT_'O_RKICHAS ciJ\o) I It.1 c".'u......,..... ,." YU 01135 3 INSPECTION ANDREPAIR 1.ke"I'e'OIWo,dlda"'III"'1I1hesp, plui! ,n"'uml"' r---cr------.................................... . WI.p."m u...,,Old .......f.., ...... ,,,., .... ".e" .....,......I .:.:.'... ... .., f!DDIIIII!I ___ Do "'01 1111 ... 1" 10 '''''I1'",n..bIn',nnl' 'o,k'ubi U'h'. mavdl"III,Ou,'y.Uk,. 6 9 7 8 21.087mm(0.830 in) < 20.087mm(0.791in) > 5.190 mm(0.204 in) < 0.015 mm(0.0006in) > 10.000 - 10.015 mm(0.3937- 0.3943 in) 9.981- 9.991mm(0.3930 - 0.3933 in) 0.009 - 0.034 mm(0.0004 - 0.0013 in) < 0.08 mm(0.0032in) > BUSHCHAIN/110 Automatic 0.08 - 0.12mm(0.003 - 0.005 in) 0.10 - 0.14 mm(0.004 - 0.006 in) ~ J " D "f 2-4 MAINTENANCE SPECIFICATIONSISPECI )Ofl Model "A" HeadDia.IN. EX. "B" Face WidthIN. EX. "c" Seat WidthIN. EX. < Limit>IN. EX. "0" Margin ThicknessIN. EX. < Limit>IN. EX. StemOutside Dia.IN. EX. < Limit>IN. EX. GuideInsideDia.IN. EX. < Limit>IN. EX. Stem-to-Guide ClearanceIN. EX. < Limit> IN. EX. StemRunoutLimit Valve Spring: FreeLengthIN. EX. < Limit>IN. EX. SetLength(ValveClosed)IN. EX. CompressedPressure(Installed)IN. EX. Tilt Limit *IN. Direction of Winding EX. IN. EX. XV250U/UC 25.9 - 26.1mm(1.020 - 1.028 in) 21.9 - 22.1mm(0.862- 0.870 in) 1.4 - 3.2mm(0.055 - 0.126 in) 1.7- 2.8 mm(0.067- 0.110 in) 0.9 - 1.1mm(0.035 - 0.043 in) 0.9 - 1.1mm(0.035 - 0.043 in) < 1.6 mm(0.063in) > < 1.6 mm(0.063in) > 1.0 - 1.4 mm(0.04 - 0.06 in) 1.0 - 1.4 mm(0.04 - 0.06 in) < 0.7mm(0.028in) > < 0.7mm(0.028in) > 6.975 - 6.990 mm(0.274 - 0.275 in) 6.960 - 6.975mm(0.273 - 0.274 in) < 6.945mm(0.273in) > < 6.920 mm(0.272in) > 7.000 - 7.012mm(0.275 - 0.276 in) 7.000 - 7.012mm(0.275- 0.276 in) < 7.05 mm(0.278in) > < 7.05mm(0.278in) > 0.010 - 0.037mm(0.0004 - 0.0015 in) 0.025 - 0.052mm(0.0010 - 0.0020 in) < 0.08 mm(0.0031in) > < 0.10 mm(0.0039in) > < 0.03 mm(0.0012in) > 29.75 mm(1.171in) 29.75 mm(1.171in) < 28.75 mm(1.131in)> < 28.75 mm(1.131in) > 25.7mm(1.012in) 25.7mm(1.012in) 7.31- 8.09 mm(16.1- 17.8 in) 7.31- 8.09mm(16.1- 17.8 in) < 2.50/1.2 mm(0.047in)> < 2.50/1.2mm(0.047in) > Right Right 25 Model Piston: Piston-to-Cylinder Clearance < Limit> Piston Size "0" MeasuringPoint "H" H Oversize: PistonRing: TopRing: Type Dimensions(BxT) EndGap(Installed) < Limit> Side Clearance(Installed) < Limit> 2ndRing: Type Dimensions (Bx T) EndGap(Installed) < Limit> Side Clearance < Limit> OilRing: Dimensions(Bx T) EndGap(Installed) ConnectingRod: Oil Clearance Crankshaft: Crank Width" A" RunoutLimit "B" BigEndSide Clearance "c" JournalOilClearance b 1st 2nd II}B I---T--l XV250U/UC 0.02 - 0.04 mm(0.0008 - 0.0016 in) < 0.1mm(0.004 in) > 48.96 - 49.00 mm(1.928 - 1.929 in) 6 mm(0.24 in) 49.25mm(1.939in) 49.50 mm(1.949in) Barrel 1 x 2 mm(0.04 x 0.08in) 0.15 - 0.30 mm(0.006 - 0.012 in) < 0.4 mm(0.016 in) >I 0.03 - 0.07mm(0;001- 0.003 in) < 0.12mm(0.005in) > Taper 1 x 2 mm(0.04 x 0.08 in) 0.15 - 0.30 mm(0.006 - 0.012in) < 0.4 mm(0.016in) > 0.02 - 0.06 mm(0.0008 - 0.0024 in) < 0.12 mm(0.005in) > 2.0 x 2.2 mm(0.078x 0.087in) 0.3 - 0.9 mm(0.012- 0.035in) 0.020 - 0.048 mm(0.0008 - 0.0019 in) 67.95 - 68.00 mm(2.675 - 2.677in) < 0.03 mm(0.0012in)> 0040- 1.05 mm(0.016 - 0.041in) 0.020 - 0.048 mm(0.0008 - 0.0019in) 2-6 ModelXV250U/UC Clutch: Friction Plate:Thickness2.9'" 3.1mm(0.114'" 0.122in) Quantity5 pcs. WearLimit< 2.5 mm(0.098in)> Clutch Plate:Thickness1.9 '" 2.1mm(0.075 '" 0.083 in) Quantity4 pcs. WarpLimit< 0.05 mm(0.002in) > ClutchSpring:FreeLength34.6 mm(1.36in) Quantity4 pc. MinimumLength< 33.6 mm(1.32in) > PushRodBendingLimit< 0.5 mm(0.02in) > Transmission: MainAxle DeflectionLimit< 0.08 mm(0.0031in) > Drive Axle DeflectionLimit< 0.08 mm(0.0031in) > Shifter: Sh ifter TypeCamDrum andGuide Bar GuideBarBendingLimit< 0.025mm(0.001in) > Carburetor: I.D. Mark2UJOOFORCALIFORNIA:3BGOO MainJet(M.J.)#110 MainAir Jet(M.A.J.)#60 Jet Needle(J.N.)4DM3-1 Needle Jet(N.J.)0-0 Pilot Jet(P.J.)#17.5 Pilot Air Jet(P.A.J.)#155 Pilot Screw(P.S.)Preset Pilot Outlet(P.O.)0.85 Bypass(B.P.1)0.8 (B.P.2)0.8 Valve Seat Size(V.S.)1.0 Starter Jet(G.S.1)#25 (G.S.2)0.7 FuelLevel13.5 '" 14.5 mm(0.53 '" 0.57in) EngineIdling Speed1,350'" 1,450 r/min VacuumPressure atIdliRQ SpeedAbove 47.9 kPa(360 mmHg,14.17inHg) VacuumSynchronous DifferenceBelow1.3 kPa(10 mmHg, 0.39inHg) FuelPump: TypeVacuum type Lubrication System: OilFilter TypePaper type OilPumpType:Trochoid type Tip Clearance0'" 0.15 mm(0'" 0.006in) < Limit>< 0.20 mm(0.008in) > Side Clearance0.03'" 0.09 mm(0.001'" 0.004 in) < Limit>< 0.09 mm(0.004in) > ReliefValveOperatingPressure441'" 539 kPa(4.5 '" 5.5kg/cm2 ,64", 78psi) 2-7 MAINTENANCE SPECIFICATIONSISPECI Pfl Model XV250U/UC Lubrication Chart: rl CAMCHAIN: ICYLINDER1 I HEAD 1CYLINDERI HEADI i CAMCHAINr-H CONNECTINGI ROD + HSTARTERCLUTCH

fRIGHT-I CRANKSHAFT-- - - - - --JOURNAL PUSHAXLEI I J MAINAXLE 8 lOILCLEANER J l I DRIVE AXLE H RELIEFVALVEI II . LOIL PUMPJ t lOlL STRAINERI I OIL PAN Ji OIL PAN J CrankcaseTightening Sequence: LEFTCASE 28 MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE Parts to be tightenedPart nameThreadsizeQ'ty Tightening torque Remarks Nmmkgftlb CamSprocket CoverBoltM6x1.0470.75.1 TappetCover- M45470.75.1 Cylinder HeadFlange boltMBx1.25B222.216 BoltM6x1.254121.2B.7 Cylinder Head(Exhaust pipe)Stud boltM6x1.0470.75.1 Spark Plug- M10 x1.252131.3B.4 Cylinder Head(Cover)BoltM6x1.0B101.07.2 Rotor (A.C.Magneto)Flange nutM121BOB.O5B ValveAdjustingLocknutNutM5x1.0470.75.1 Rocker Arm Shaft StopperBoltM6x1.02121.2B.7 CamSprocketBoltMBx1.252262.619 ChainGuideBoltM6x1.04101.07.2 Chain TensionerBoltM6x1.04101.07.2 Chain TensionerEndCapboltMBx1.252BO.B5.B OilPump CoverScrewM6x1.0170.75.1 OilStrainer CoverScrewM6x1.0170.75.1 OilPumpScrewM6x1.0370.75.1 OilFilter CoverScrewM6x1.0370.75.1 Drain Plug- M35 x1.51323.223 Carburetor JointBoltM6x1.04101.07.2 Air Filter ElementScrewM6x1.0270.75.1 Air Filter CoverBoltM6x1.02101.07.2 ExhaustPipe 3Flange boltMBx1.252202.014 ExhaustPipe Joint (Lower)Flange boltMBx1.251202.014 Exhaust Pipe " FlangenutM6x1.04101.07.2 MufflerFlange boltMl0xl.251252.5lB Exhaust Pipe Joint (Upper)Flange boltM6x1.01101.07.2 Air Filter PlateFlange boltM6x1.02101.07.2 ScrewM4x1.0230.32.2 CrankcaseScrewM6x1.01470.75.1 CrankcaseCover(Left)ScrewM6x1.0970.75.1 Crankcase Cover(Right)ScrewM6x1.01070.75.1 Cover(Drive chain)ScrewM6x1.0370.75.1 Drain Plug- M14x 1.251343.424 Nozzle- MBx1.25250.53.6 Starter ClutchBoltMBx1.253303.022Stake ...g Primary Drive GearNutM16 x1.01BOB.O5BUselock washer Clutch BossNutM16 x1.01757.554Uselock washer Clutch SpringScrewM6x1.04BO.B5.B Clutch AdjusterLocknutNutM6x1.01BO.B5.B Clutch PushLeverScrew.MBx1.01121.2B.7 Drive SprocketBoltM6x1.02101.07.2 Shiftcam Side PlateScrewM5x O.B140.42.9 ..g Shiftcam StopperScrewMBx1.01222.216 ..g Shift Lever 3BoltM6x1.01BO.B5.B Shift PedalNutM6x1.01BO.B5.BLeft-hand thread NutM6x1.01BO.B5.B Neutral Switch- Ml0 x1.251202.014 StatorScrewM6x1.0370.75.1 Pickup CoilScrewM5x1.0250.53.6 Starter MotorBoltM6x1.02101.07.2 2-9 MAINTENANCE SPECIFICATIONSISPECI Pfl Chassis ModelXV250U/UC SteeringSystem: SteeringBearing TypeBall bearing Number/Size of SteelBall:Upper19 pcs./0.25in Lower19 pcs./0.25in Front Suspension: FrontForkTravel140 mm(5.5in) Fork SpringFreeLength415mm(16.3in) < Limit>< 410 mm(16.1in) > SpringRate:Kl3.92N/mm(0.4 kg/mm, 22.4 Ib/in) K25.69N/mm(0.58kg/mm, 32.5Ib/in) StrokeKl0- 106 mm(0 - 4.17in) K2106 - 162mm(4.17- 6.38in) Optional SpringNo. Oil Capacity245 cm3 (8.62Imp oz, 8.28US oz) OilLevel120 mm(4.72in) From top of fully compressedinner tube without fork spring Oil GradeYamahafork oill0wt or equivalent Rear Suspension: Shock Absorber Travel70 mm(2.76in) SpringFreeLength233 mm(9.17in) < Limit>< 226 mm(8.90in) > FittingLength207.5 mm(8.1l-in) SpringRate:Kl15.7N/mm(1.6 kg/mm, 89.6 Ib/in) K222.6 N/mm(2.3 kg/mm,128.8 Ib/in) Stroke:Kl0- 75mm(0 - 2.95in) K275 - 162mm(2.95 - 6.38in) Optional SpringNo. Swingarm: SwingarmFreePlayLimit:End< 1 mm(0.04 in)> Front Wheel: TypeSpoke wheel Rim SizeMT1.60 x18 Rim MaterialSteel RimRunoutLimit:Vertical< 2 mm(0.08in) > Lateral< 2 mm(0.08in)> RearWheel: TypeSpoke wheel Rim SizeMT2.75 x15 RimMaterialSteel RimRunoutLimit:Vertical< 2 mm(0.08in) > Lateral< 2 mm(0.08in)> Drive Chain: Type/Manufacturer5200S/0.1.0. No. of Links140 Drive ChainSlack30 - 40 mm(1.18 - 1.57in) 2-10 ModelXV250U/UC FrontDiscBrake: TypeSingle Disc OutsideDiameter x Thickness267x 5 mm(10.5x 0.2in) PadThickness6.8mm(0.27in) < Limit>* < 0.8 mm(0.03in) > , MasterCylinderInsideDiameter12.7mm(0.45in) Caliper CylinderInside Diameter38.1mm(1.50in) Brake Flu idTypeDOT #3 or #4 RearDrumBrake: TypeLeading andtrailing DrumInsideDiameter130 mm(5.12in) < Limit>< 131mm(5.16 in)> Lining Thickness4 mm(0.16 in) < Limit>< 2 mm(0.08in) > Shoe SpringFreeLength36.5 mm(1.44 in) BrakeLever andBrake Pedal: BrakeLeverFree Play2 - 5 mm(0.08 - 0.20 in) Brake PedalPosition45- 55mm(1.77- 2.17in) BrakePedalFreePlay20 - 30mm(0.8 - 1.2 in) ClutchLever: ClutchLeverFreePlay3 - 5 mm(0.12- 0.20 in) 2-11 MAINTENANCE SPECIFICATIONSISPECIjOfl TIGHTENING TORQUE: Part to be tightenedThreadsize Tightening torque Remarks Nmmkgftlb Front WheelAxleM14 x1.55S5.S42 Front Axle BoltMSx1.25202.014 SteeringStem andInner TubeM12xl.253S3.S27 FrontFender andFront ForkMSx1.25202.014 Front Brake Caliper andFrontForkMl0 x1.25353.525 Steering Stem andClampM6x1.070.75.1 Headlight Stay andSteering StemM6x1.070.75.1 Headlight Stay andHeadlight(Lower)MSx1.25202.014 Handlebar Crown andI nner TubeMSx1.25202.014 Handlebar Crown andSteering StemM14xl.25545.439 Steering Stem andRingNutM25 x1.03S3.S27SeeNOTE Handlebar Crown andHandlebar Ml0 x1.25202.014 Holder (Lower) Handlebar andHandlebarHolder (Upper)MSx1.25202.014 Speedometer andHandle CrownM6x1.070.75.1 Headlight (Upper)andMeter StayM6x1.070.75.1 Indicator Light Box andMeter StayM4x 0.710.10.7 Headlight Stay andFlasherLight StayM12 x1.25202.014 Front Brake Disc andHubMSx1.25202.014 Uselock-c washer Front BrakeHose andCaliperMl0 x1.25262.619 Front Brake BleedScrewMSx1.2560.64.3 Master Cylinder andBrakeHoseMl0 x1.25262.619 Master Cylinder andCapM5x O.S20.21.4 Master Cylinder andBracketM6x1.090.96.5 Horn andFrameM6x1.070.75.1 Frame andIgnition CoilStayM6xl.070.75.1 Ignition Coil andCoilStayM5x O.S40.42.9 Engine Stay(Front)andFrameMl0x 1.25555.540 Igniter Unit andFender(Rear)M6x1.040.42.9 AirFilter CaseandFrameM6x1.040.42.9 Engine Stay(Rear)andFrameMSx1.25353.525 Engine Mounting (Rear-Top)andStayMSx1.25353.525 Engine Mounting (Rear-Bottom)andFrameMSx1.25353.525 Engine Mounting (Front) andFrameMSx1.25353.525 Main Switch andFrame M6x1.0151.511 Regulator andFrame M6x1.070.75.1 Helmet Hanger andFrameM6x1.0151.511 Brake PedalAdjusterLocknutM6x1.070.75.1 Sidestand Ml0x 1.25262.619 RearFootrest andFrameMSx1.25303.022 Pivot Shaft andSwingarmM12 x1.25434.331 FuelPump andPumpBracketM6x1.070.75.1 PumpBracket andFuelTankM6x1.070.75.1 FuelCock andFuelCock StayM6x1.070.75.1 FuelTank andFuelCock StayM6x1.070.75.1 FuelTank(Rear-Top) andFrameM6x1.090.96.5 Battery Box andFrameM6x1.070.75.1 Bracket1 andReinforcement(RearFender)M6x1.070.75.1 Seat(Front)andFrameM6x1.070.75.1 Seat(Rear)andReinforcementM6x1.070.75.1 2-12 MAINTENANCE SPECIFICATIONSISPEC/ Pfl Partto be tightenedThreadsize Tightening torque Remarks Nmmkgftlb RearShockAbsorber (Upper)MSx1.25202.014 RearShock Absorber (Lower)MSx1.25202.014 Rear WheelAxleM14 x1.510510.575 RearFender (Front) andFrameMl0 x1.25606.043 RearFender (Rear)andFrameMl0 x1.25606.043 RearFender andFlasherLight StayM12xl.25202.014 RearFender andTaillightM6x1.070.75.1 RearFender andLicenceBracketM6x1.070.75.1 BrakeRod andSwingarmMSx1.25202.014 BrakeRodandBrake Shoe PlateMSx1.25202.014 Sidestand Switch andSidestandBracketM5x1.030.32.2 Sidestand Switch PannelandFrameM6x O.S131.39.4 FlasherLight andFlasher StayM6x1.070.75.1 WireHarness andFrameM6x1.040.42.9 NOTE: __________________________________________________________ 1.First, tightentheringnut approximately 3SNm(3.Sm' kg,27ftlb)by using the torque wrench, thenloosen the ringnut one turn. 2.Retighten the ring nut 10 Nm(1.0 mkg, 7.2 ftlb). 213 ". MAINTENANCE SPECIFICATIONSISPECIjOfl Electrical ModelXV250U/UC Voltage:12V Ignition System: Ignition Timing(B.T.D.C.)8 at1,300 r/min AdvancedTiming(B.T.D.C.)27 at 3,000 r/min AdvancerTypeElectrical 30 CI .!:-Eu i=ci 20 c::.....= / o. :-e~c:: I CI 10 ~-0246810 Engine Speed( x103 r/min) T.C.I.: Pickup CoilResistance(Color)178 - 266nat 20C (68F) (Blue/Yellow - Green/White) T.C.I.Unit-Model/ManufacturerQCA03/NIPPONDENSO Ignition Coil: Model/ManufacturerJ0226/NIPPONDENSO Primary WindingResistance3.2- 4.8nat 20C(68F) Secondary WindingResistance10.4 - 15.6 kn at 20C(68F) SparkPlugCapResistance10 kn Charging System/Type:A.C.magneto generator A.C.Generator: Model/ManufacturerLMZ42/NIPPONDENSO NominalOutput14V, 21A at 5,000 r/min 30 ~.... c:: Q) t20, :::J/ (.) .... :::J0. J .... 10 :::J/ 0 I 0246810 Engine speed( x103 r/min) Stator CoilResistance10.19 - 0.29nat 20C (68F)(White - White) 2-14 MAINTENANCE SPECIFICATIONS ModelXV250U!UC VoltageRegulator: Type .. , Short circuit Model/Ma nufactu reSH569/SHINDENGEN NoLoadRegulatedVoltage14.3 - 15.3V Rectifier: Model/Ma nufactu rerSH569/SH INDENGEN Capacity25A WithstandVoltage200V Battery: Capacity:12V,10AH Specific Gravity1.280 Electric Starter System: TypeConstant mesh type Starter Motor: Model/Manufacturer2UJ/MORIYAMA Output0.4kW Brush OverallLength10 mm(0.39in) < Limit>< 3.5 mm(0.14 in) > SpringPressure560 - 840 g (19.8 - 29.7oz) Commutator: OutsideDiameter22mm(0.87in) < WearLimit>< 21mm(0.83in) > MicaUndercut1.5 mm(0.059in) StarterRelay: Model/ManufacturerA 104-128/HITACHI AmperageRating100A Coil WindingResistance3.0 - 3.7nat 20C(68F) Heater(Carburetor): Resistance9.5 - 10.5nat 20C(68F) Horn: Type/QuantityPlain type x1 Model/ManufacturerMF-12/NIKKO Maximum Amperage1.5A FlasherRelay: TypeSemitransister type Model/ManufacturerFB257H/NIPPONDENSO Self CancellingDeviceYes. FlasherFrequency75 - 95 cycle/min Wattage27W x 2 + 3.4W Self CancellingUnit: Model/ManufacturerFB257H Starting Circuit Cut-offRelay: Model/Manufacturer2UJ/OMRON DiodeYes Circuit Breaker: TypeFuse Amperage for IndividualCircuit x Quantity: Main20A x1 Signal10A x1 2-15 GENERAL TORQUE SPECIFICATIONS/ISPECI6\OI DEFINITION OFUNITS__ rI_ GENERAL TORQUE SPECIFICATIONS Thischart specifies torque for standardfasteners withstandardI.S.0. pitch threads.Torque speci-ficationsforspecialcomponentsorassemblies areincludedintheapplicablesectionsofthis book.Toavoidwarpage,tightenmultifastener assembliesina crisscrossfashion,inprogressive stages,untilfulltorqueisreached.Unless other-wisespecified,torquespecificationscallfor clean,drythreads.Componentsshouldbeat room temperature. A:Distance acrossflats B:Outside thread diameter DEFINITION OFUNITS UnitRead mmmillimeter cmcentimeter kgkilogram NNewton NmNewton meter mokgMeter kilogram PaPascal N/mnNewton per millimeter LLiter cm3 Cubic centimeter r/minRotation per minute A (Nut) 10mm 12mm 14mm 17mm 19mm 22mm Definition 10-3 meter 10-2 meter 103 gram 1kg xm/sec2 Nxm m xkg N/m2 N/mn --2-16 B Generaltorque specifications (Bolt) Nmmokgftolb 6mm60.64.3 8mm151.511 10mm303.022 12mm555.540 14mm858.561 16mm13013.094 Measure Length Length Weight Force Torque Torque Pressure Spring rate Volume or Capacity Engine Speed LUBRICATION POINTS ANDLUBRICANT TYPE LUBRICATION POINTS ANDLUBRICANT TYPE ENGINE Lubrication PointSymbol Oil seallip ~a-Ring ~Bearing -.e Cylinder headbolt/Washer - ~Rocker shaft bearing -G Crankshaft pin ~Crankshaft journal -1m Connecting rod-(51 Piston surface - ~Piston pin -1m Camshaft camlobe/Journal -1m Valve stem(IN, EX) -El Valve stemend(IN, EX) - ~Camchain/Camsprocket - ~Oil pump shaft, rotor (IN, OUT), housing -ca Idle gear1,2 surface/Bushing ..-.m Starter clutch -G Primary drivengear - ~Pushlever axle -G Transmission gear(Wheel/Pinion) -G Axle (Main/Drive) -IGJ Shift cam -IGJ Shift fork/Guide bar -1m Crankcasemating surfaces Replacecrankshaft and/or bearing. ~ RunoutLimit: 0.03 mm(0.001inl .Side clearance Outof specification-->Replaceconnecting rod. BigEndSide Clearance: 0.40 ~ 1.05 mm( 0 . 0 1 6 ' ~ 0.041in) ____________ 4-36 TRANSMISSION ShiftFork 1.Inspect: .Shift forks Onthegearandshiftcamcontactsur-faces. Wear/Chafing/8ends/Damage --+Replace. 2.Check: .Shift forkmovement Onits guidebar. Unsmooth operation --+Replace fork and/or guidebar. Shift Cam 1.Inspect: .Shift cam grooves Wear/Damage/Scratches --+Replace. Shift cam segment Damage/Wear --+Replace. Shift cambearing Pitting/Damage --+Replace. Main/Drive Axles and Gears 1.Measure: Axlerunout CD UsethecenteringdeviceandDialGauge . Out of specification --+Replace. RunoutLimit: 0.08 mm(0.0031in) 2.Inspect: Gears Damage/Wear --+Replace. 3.Check: Gearmovement Unsmoothoperation--+Replace. 4.Inspect: Mating dogs Cracks/Wear/Damage --+Replace. INSPECTIONANDREPAIR1ENG 1'-1 4-37 NOTE: __________________________ Whenreplacingthemainaxleorpinions,take the following steps: - Applymolybdenumoi Itothe4thCDand5th pinion gearbosses. - Usingahydraulicpress;force-fitthe2nd pinion gear to the position specified . 2nd Pinion Gear Position : 87.2 - 87.4 mm (3.43 - 3.44 in) -After installingthepinions onto themainaxle, makesurethe4thand5thpiniongearsturn freely. BEARINGS 1.Inspect: -Axle bearings -Shift cambearing Pitting/Damage -+Replace. CIRCLIPS AND WASHERS 1.Inspect: -Circlips - Washers Damage/Looseness/Bends -+Replace. ENGINEASSEMBLY AND ADJUSTMENT ENGI\.I 4-38 ENGINE ASSEMBLY AND ADJUSTMENT TRANSMISSION AND CRANKSHAFT 1.Install: Transmission Shift camCD Shift forks Guide bar(Rear- Longer) Guide bar(Front - Shorter)@ NOTE: _________________________ Eachshiftforksisidentifiedby anumbercast onitsside.Allthenumbersshouldface the left side. 2.Check: Shifter operation Unsmooth operation -+Repair. NOTE:__________________________ .Oil eachgear andbearing thoroughly. Beforeassemblingthecrankcase,besurethat thetransmissionisinneutral and that the gears turn freely. 3.Install: CrankshaftCD Into the crankcase(Left). NOTE:__________________________ Installthetaperedendof thecrankshaft(Left side)into the crankcase . Aligntheleftconnectingrodwiththerear cylinder sleevehole . Therodmustbeinthisholewhenthe crank-shaftisproperly installed. ________TRANSMISSION CDDriveaxle Bearing Circlip @Washer Wheelgear(1st)(38T) Wheelgear(4th)(28T) (j) Wheelgear(3rd)(35T) RUNOUT LIMIT: 0.08 mm(0.0031in) 2 Wheelgear(5th)(29T) Wheelgear(2nd)(38T) @Mainaxle (j]) Pinion gear(4th)(24T) Pinion gear(3rd)(24T) @ Pinion gear(5th)(30T) @ Pinion gear(2nd)(20T) 4-39 87.287.4 mm (3.433.44in) ENGINE ASSEMBLY AND ADJUSTMENT IENGI\.I -------------------------------------------------------CRANKSHAFT CDPistonring set Piston Pistonpin @Connecting rod @Crankpin Crank(R ight) (j)Crank(Left) Woodruff key AI TOPRING SIDE CCLEARANCE LIMIT: D ENDGAP LIMIT: CRANK WIDTH: F69. 75 ~ 6S.00 mm (2.675 ~ 2.677in) 8------------CRANKSHAFT GRUNOUTLIMIT: ?.. 03mm(0.0012in) 0.12 mm (0.005in) 0.4mm (0.016in) BI 2NDRING 0.12 mm (0.005in) 0.4 mm (0.016in) 7 BIGEND SIDE CLEARANCE: 0.40 ~ 1.05 mm(0.016 ~ 0.041in) OJ"Y" mark towards theoutside. [KJFor rearcylinder [] For front cylinder PISTON-TO-CYLINDERCLEARANCE: 0.02 ~ 0.04 mm(O.OOOS~ 0.0016 in) USENEW ONE p V r--IV RBrL .......'IR - --@ I B

... ,.------R/W-------+----R/W RIW---e----+-R/W----, 16 ,------1R/W @II I.... __ ...! liLlY 1:I @r- ------ --,, 6 L/Y II1I@ IL__ J:? IB/YIB 1LlW1..1. II-=-I1 @L_____________J R/W ........---I RIY1n

LlJ1 @ B L ..... --BrBr BrBr 66 @@ @II @ P Gq 16 . IQ@@ Br/WY/R LIB i Y B I ... v==n -L Y R R ChOg LIB BBBB ............ @@@ 7-33 w w W @ 0 -WIG W/R@ _________________________L_,G_H_T_,N_G_S_Y_S_TE_M__ IELECIIii 1 Aforementioned circuit diagramshows lighting circuit in circuit diagram. NOTE: For the color codes,seepage7 -2. CD Mainswitch @Battery Fuse"MAIN" "START" switch @ "LIGHTS" (Dimmer)switch @"HIGH BEAM" indicator light (@Headlight @Meter light @Taillight @ Front position light (Left) Front positionlight (Right) 7-34 LIGHTING SYSTEMIELECIIiiii I TROUBLESHOOTING HEADLIGHT/"HI BEAM" INDICATOR LIGHT DONOT COMEON Procedure Check; 4.Fuse"MAIN"1.Headlight bulb/"H I BEAM" indicator light bulb5. "LIGHTS" (Dimmer)switch 6.Mainswitch2.Headlight bulb socket/"H IGHBEAM" indicator light bulb socket7.Wiring connection(Lighting system) 3.Battery NOTE:____________________________________________________________ - Removethe following parts before troubleshooting. 1)Seat3)Handlebar 2) Headlight4)Indicator lights box - Use the following specialtool in this troubleshooting. ~ Pocket Tester: ~ YU-03112 1.Bulb - Remove the bulb. Referto"CHAPTER3.HEADLIGHT BULBREPLACEMENT". -ConnectthePocketTester(nx1)tothe bulb terminals. Tester (+)Lead -+TerminalCD Tester(-) Lead -+Terminal Tester (+)Lead -+TerminalCD Tester(-) Lead -+Terminal -Check the bulb for continuity. ..(1.. CONTINUITY * 2 NOCONTINUITY IReplacebulb. 735 l ______ -------------------L-IG-H-T-IN-G-S-Y-S-TE-M--IELECIIii I * g 2.Bulbsocket ,Disconnectthebulbsocketleadsfromthe wire harness. -I nsta IIthe bu Ibto the bu Ibsocket. -ConnectthePocketTesterIn,x1)tothe bulb socketleads. Tester(+)Lead-+Yellow CDLead Tester(-I Lead -+Black Lead Tester(+)Lead -+Green Terminal Tester (-) Lead-+Black Lead .. Checkthe bulb socketfor continuity. ~ CONTINUITY 3.Battery Checkthe battery condition. Checkthebatteryfluidlevel,battery termi-nals andspecific gravity. Specific Gravity: 1.280 at 200e (G8F) ~ CORRECT 4.Fuse"MAIN" ConnectthePocketTester"Qx1" tothe fuse. Checkthe fusefor continuity . ..[l. CONTINUITY * Tester (+)Lead -+YellowCDTerminal Tester {-I Lead -+Black Terminal 7-36 NOCONTINUITY I Replacebulbsocket. INCORRECT Refill battery fluid. Cleanbattery terminals. Recharge or replace battery. NOCONTINUITY l I Replacefuse. --------5."LIGHTS" (Dimmer)switch - ConnectthePocketTester(nx1)tothe headlight bulb socket. Whenturning"LIGHTS"(Dimmer)switch to "HI". Tester(+)Lead-+YellowQ) Terminal Tester (-) Lead-+Black Terminal Whenturning"LIGHTS"(Dimmer)switch to "LO". Tester(+)Lead -+Green Terminal Tester (-) Lead-+Black Terminal 1'-CD ~lLI i y ~~) ~ G ! c:J2 3 _9@9 ~L--Turn the "LIGHTS" (Dimmer)switch to the "HI" and"LO". -Checkthe"LIGHTS"(Dimmer)switchfor continuity. SwitchGood Bad condition positioncondition HI0X0X LO00XX 0:ContinuityX:Nocontinuity ~ GOODCONDITION 6.Main switch - Disconnectthe main switch coupler Q)from the wire harness. - ConnectthePocketTester([2x1)tothe main switch. Tester(+)Lead-+Brown Terminal Tester(-) Lead -+Red Terminal 7-37 LIGHTING SYSTEMIELECIIiilI NOTE:____________________ The"LIGHTS"(Dimmer)switchis connectedwiththeheadlightbulb socket. BAD CONDITION l IReplacehandlebar switch(Left). ______________--------___L_IG_H_T_IN_G_S_Y_S_TE_M__IELECIiii 1 Turnthe mainswitch to liON" and"OF F". Checkthe mainswitchfor continuity. SwitchGood Bad condition positionOFF0XX0 ONX0X0 BAD CONDITION i 0:ContinuityX:NocontinuityIReplacemainswitch. G00D CONDITION 7.Checkentirelightingsystemforconnec-tions.POORCONNECTION __R_ef_e_r_to__"_W_I_R_IN__G_D__IA_G__R_A_M_'_'_se_c_ti_o_n_. __..... OK I the chargingsystem. 7-38 LIGHTINGY S T ~ M IELECIIii I TAILLIGHT/FRONT POSITIONLIGHT/METERLIGHT DO NOT COMEON. Procedure 1.Taillight bulb/Front positionlight bulb/ Meter light bulb. 2.Taillight bulb socket/Front positionlight bulb socket/Meterlight bulb socket. NOTE: 3.Battery 4.Fuse"MAIN" 5.Main switch 6. Wiring connection(Lighting system) Remove the following parts before troubleshooting. 1 ) Seat3)Lense(Front flasher/Frontpositionlight) 2) Lense(Taillight)4)Headlight Use the following special toolin this troubleshooting. ~ Pocket Tester: ~ YU-03112 1. Bulb Remove the bulb . ConnectthePocketTester(nx1)tothe bulb. Tester(+)Lead ~ TerminalQ) Tester(-) Lead ~ Terminal Tester(+)Lead ~ TerminalQ) Tester(-) Lead ~ Terminal .Check the bulb for continuity. -@+ ~ CONTINUITY 2.Bulb socket .Disconnetthebulbsocketleadsfromthe wireharness . ConnectthePocketTester(nx1)tothe bulb socketleads. 2 NOCONTINUITY I Replacebulb. 739 Tester(+)Lead~ BlueCDLead Tester(-) Lead~ Black Lead I ,/ " ,I ,I II I.'----_J" 1\ I \ ......... Checkthe bulb socketfor continuity. ~ CONTINUITY 3.Battery Checkthe battery condition. Checkthebatteryfluidlevel,battery termi-nals andspecific gravity. Specific Gravity: 1.280 at 20C (68F) ~ CORRECT 4.Fuse"MAI N" ConnectthePocketTester"nx1" to the fuse. Check the fusefor continuity. ~ CONTINUITY 5.Main switch Disconnectthe main switch couplerCDfrom the wire harness. ConnectthePocketTester(nx1)tothe main switch. Tester(+)Lead ~ Brown Terminal Tester (-) Lead ~ Red Terminal Tester(+)Lead ~ Blue@Terminal Tester (-) Lead ~ Red Terminal 7-40 LIGHTING SYSTEMIELEcl1iii I NOCONTINUITY l I Replacebulb. INCORRECT i Refill battery fluid. Cleanbattery terminals. Recharge or replace battery. NOCONTINUITY l IReplacefuse. -Turnthemainswitchto"OFF", "ON" and liP". - Checkthe mai n switchfor conti nu ity. SwitchGood Badcondition positioncondition OFF0XX0 ONX0X0 P0XX0 0:ContinuityX:Nocontinuity GOODCONDITION 6.Checkentirelightingsystemforconnec-tions. - Refer to "WI RINGD lAG RAM" section. ~ OK ICheck the charging system. LIGHTING SYSTEMIELECIiii I BAD CONDITION l IReplacemainswitch. POORCONNECTION ICorrect. 7-41 LIGHTING SYSTEMIELECIIii I -MEMO-7-42 SIGNAL SYSTEMIHEel iii I SIGNAL SYSTEM CIRCUIT DIAGRAM CD

OFF ON p RBrL IU K..J.J IU

RBrL 'R - --@ J: '----L/W-------, B ..I-W W w------I RM'-----4-------+-R/W-----..., 16 r------r RM @II I.- __ J IIUY I:I @r- ------ --,16L/Y IIII@ IL__ JI0 I'II ....._-4-B/YIB IuwIJ. II-= II @L_____________J o R/W--"""""'" R/Yln

l/J t @ L Gy BrBrBrBr @Io 1@) Q SbP G/YI1 @@BrMY/R Yi?P-_....... I Lv==n UB YR

R Ch L----L/B---+-+-+----. BBBB .- .- ...... @(@@ 7-43 __________________________S_IG_N_A_L_S_Y_S_TE_M__ IELECI~ IAforementioned circuit diagram shows signalcircuit in circuit diagram. NOTE:___________________________________________________________ For the color codes,seepage 7-2. CD Mainswitch @Battery Fuse"MAIN" @Fuse "SIGNAL" @Front brake switch (j]) Rearbrake switch @"NEUTRAL" indicator light Neutralswitch @Horn @"HORN" switch @Flasher relay @ Cancellingunit @"TURN" switch Reedswitch @ "TURN" indicator light @Brake light @ Front flasher light (Left) @Rearflasherlight (Left) @ Rearflasherlight (Right) @Frontflasher light (Right) 7-44 _________________________S_IG_N_A_L_S_YS_T_E_M_IELECliiil eTurnthemainswitchto"ON" and"OFF". eCheck the mainswitch for continuity. SwitchGood positioncondition Bad condition OFF0XX0 ONX0X0 o: ContinuityX:Nocontinuity ~ GOODCONDITION 4.Wiring connection Checkthe entire signalsystemfor connections. Refer to the "WI RINGDIAGRAM" section. ~ CORRECT Gotothe"SIGNALSYSTEMTESTAND CHECK" section. BAD CONDITION 1 IReplacemain switch. POORCONNECTION 1 ICorrect. 7-46 __________________________S_IG_N_A_L_S_Y_S_TE_M__ IELECliiil SIGNAL SYSTEM TEST AND CHECK FLASHERLIGHT DOES NOT BRINK. 1.Bulb - Remove the bulb. - ConnectthePocketTester(nxl)tothe bulb. Tester (+)Lead-+TerminalCD Tester (-) Lead-+Terminal -+Terminal -Check the bulb for continuity. CONTINUITY 2.Bulbsocket -Install the bulb to the socket. - Disconnecttheflasherlightleadsfromthe wireharness. - ConnectthePocketTester(nxl) tothe flasherlightleads. When checking right flasherlight: Tester (+)Lead -+Dark greenCDLead Tester (-) Lead -+Black@Lead When checking left flasherlight: Tester (+)Lead -+ChocolateLead Tester (-) Lead -+Black@Lead

Ch __ ........c:J 2 NOCONTINUITY 1 I Replacebulb.

Ch __ ........c:J 7-47 - Checktheflasherlight bulbsocketfor con-tinuity. ~ CONTINUITY 3. "TURN" switch -Disconnectthe"TURN"switch(Left handlebarswitch)couplerCDfromthe wire harness. - ConnectthePocketTester(Qx1)tothe "TU RN" switch Whenturning "TURN" switch to "RIr; Tester(+)Lead"""*Brown/White Lead Tester(-) Lead"""*Dark green Lead Whenturning "TURN" switch to "L"; Tester(+)Lead"""*Brown/White Lead Tester(-) Lead"""*Chocolate@Lead _ Turnthe"TU R N"switchtothe"R"and IlL". -Check the "TU RN" switch for continuity. SwitchGood Bad condition positioncondition R0X0X L00XX 0;ContinuityX:No continuity n GOOD ~ CONDITION 4.Voltage -Disconnect the flasherrelayCDcoupler from the wire harness. -Turn the main switch to "ON". -Turn the "TURN" switch to the "R" or ilL". -ConnectthePocketTester(DC20V)to the flasherrelay coupler. Tester (+)Lead"""*Brown Terminal Tester(-) Lead"""*Ground 7-48 SIGNAL SYSTEMIELECIIlliii I NOCONTINUITY IReplaceflasherlight bulb socket. BAD CONDITION IReplacehand lebar switch(Left). Checkthe flasher voltage. Flasher Voltage: 12.0V n MEET ~ SPECIFICATION IReplaceflasherrelay. 7-49 SIGNAL SYSTEMIELECIIiiii I OUT OFSPECIFICATION l 5.Wiring connection Checktheentiresignalsystemfor connections.Refertothe"WIRING DIAGRAM" section. __________________________S_IG_N_A_L_S_Y_ST_E_M__ IELEclIii 1 FLASHERLIGHT DOES NOT CANCEL. 1."TURN" switch Disconnectthe"TURN"switch(Left handlebarswitch)couplerCDfromthe wire harness . ConnectthePocketTestertotheswitchto coupler. Tester (+)Lead -+Yellow/Red Terminal Tester (-) Lead -+Ground Check the followingfor continuity . Pushthe"TU RN"switchtoleftorright. Oncetheswitchisreleaseditwillreturnto the center position. Tocancelthe signal,push the switchinafter ithasreturnedto the center position. "TURN" SwitchGood BadCondition PositionCondition ilL" and"R"00XX liN" (Cancel)X0X0 0:ContinuityX:Nocontinuity ~ GOOD CONDITION 2.Reedswitch Disconnectthespeedometercoupler CD fromthe wireharness . ConnectthePocketTestertothespeed-ometer coupler. Tester (+)Lead-+White/Green Terminal Tester(-)Lead -+Black@ Terminal. 7-50 BADCONDITION l "TURN" switchisfaulty. Replacehandlebar switch(Left). Liftthefrontwheelandrotatethe wheelbyhand,andmeasurethereed switchresistance. Reed SwitchResistance: About 7n Thenreturnback Onor 00 when wheelis stopped. n BOTHRESISTANCES ~ MEET SPECIFICATION 3.Wiring connection check Entire signalsystem Referto "WIRINGDIAGRAM". ~ O KIReplace the flasher relay. 751 SIGNAL SYSTEMIHEel i1Ii!iIl ,L WARNING: Securelysupportthemotorcycleso there isno danger of it falling over. POORCONNECTION I Correct connection(s). __________________________S_IG_N_A_L_S_Y_S_TE_M__ IELECIIii I BRAKE LIGHT DOES NOT COME ON. 1.Bulb Remove the bulb . ConnectthePocketTester(Qx1)tothe bulb. Tester(+)Lead -+TerminalCD Tester(-)Lead -+Terminal Tester(+)Lead -+TerminalCD Tester(-) Lead -+Terminal Check the bulb for continuity. ~ CONTI NU ITY 2.Bulb socket Disconnetthebulbsocketleadsfromthe wireharness . ConnectthePocketTester(Qx1)tothe bu Ibsocketleads. Tester(+)Lead -+YellowCDLead Tester(-) Lead -+Black Lead =-- = = - ~ CD ~ : - { >2 Check the bulb socket for continuity. ~ CONTINUITY * NOCONTINUITY i I Replacebulb. NOCONTINUITY 1 I Replace bulb socket. 7-52 _________________________S_IG_N_A_L_S_YS_T_E_M_IELECIIiiI 3.Front brake switch Disconnectthefrontbrakeswitchcoupler CDfrom the wireharness . ConnectthePocketTester(51x1)tothe brake switch coupler. Tester(+)Lead -+Brown Terminal Tester(-) Lead -+Green/Yellow Terminal Checkthe brake switch for continuity. SwitchGood positioncondition Bad condition o Front brake 0X is applied. x oX Front brake is not applied. Xo 0:ContinuityX:Nocontinuity nGOOD 'CONDITION 4.Rearbrake switch Disconnect the rear brake switch couplerCD from the wire harness. ConnectthePocketTester(51x1)tothe brake switch coupler. Tester(+)Lead -+Brown Terminal Tester(-) Lead -+Yellow Terminal 1-_______--'-_______--17-53 BAD CONDITION 1 IReplacefront brake switch. ____________ --------------S-,G-N-A-L-S-Y-S-TE-M--IElECIIii 1 Check the brake switch for continu ity. SwitchGood Badcondition positioncondition Rearbrake 0 isappliect. Rear brake X isnot applied! 0:ContinuityX: 5.Wiring connection XX 0X Nocontinuity GOOD CONDITION 0 0 Checktheentiresignalsystemforconnec-tions.Refertothe"WIRINGDIAGRAM" section. ~ CORRECT t e p l a ~ e tail/brakelight bulb socket. BAD CONDITION 1 IReplacerear brake switch. POORCONNECTION 1 ICorrect. 7-54 SIGNAL SYSTEMIHEel iiiii I "NEUTRAL" INDICATOR LIGHT DOES Nor COMEON. 1.Bulb - Remove the bulb. - ConnectthePocketTester(nx1)tothe bulb. Tester(+)Lead -+TerminalQ) Tester (-) Lead -+Terminal 00 G:J IIJI? i 2 Crt -@+ Ci> J -Check the bulb for continuity. ~ CONTINUITY 2.Bulbsocket - DisconnecttheindicatorlightscouplerQ) from the wire harness. - ConnectthePocketTester(nxl) tothe coupler. Tester(+)Lead-+Brown Terminal Tester (-) Lead -+Sky blue Terminal - Checkthe bulb socketfor continuity. ~ CONTINUITY * 7-55 NOTE! ________ __ _______ Removethehandlebarandindicator lights box. NOCONTINUITY l IReplacebulb. NOCONTINUITY l IReplacebulb socket. 3."NEUTRAL" switch - Disconnecttheneutralswitch/pickupcoil couplerCDfrom the wire harness. -ConnectthePocketTester(nx1)tothe "N EUTRAL" switch. (+)Lead -+Sky blue Terminal Tester(-) Lead -+Ground (j) J; 1:::- ...... )w/GlwlR/Sb J '" W , I:.J , ,/ " h "(,I) G:J V \\liEJ ,. f=..\ \.= Qrr.\'; I__ J

I -= -Shift the transmissionin neutral andgear. -Checkthe"NEUTRAL"switchforcon-tinuity. TransmissionGood Bad condition positioncondition Neutral0 GearX 0:Continuity XX 0X X:Nocontinuity n GOOD 4.Wiring connection 0 0 Checktheentiresignalsystemforconnec-tions.Refertothe"WI RINGDIAG RAM" section. SIGNAL SYSTEMIELECIIiiii I BAD CONDITION 1 IReplace"NEUTRAL" switch. 7-56 SIGNAL SYSTEMIELECI_1 HONEDOES NOT SOUND, WHENPUSHING"HORN" SWITCH. 1."HORN" switch -Disconnectthe"HORN"switchleadsfrom the wire harness. -ConnectthePocketTester(rlxl)tothe switchleads. Tester(+)Lead -+PinkCDLead Tester(-) Lead -+Black Lead l=?1 - ~~i ~- ~c:J 9@9 ~L..JL-- Checkthe"HORN" switch for continuity. SwitchGood Bad condition positioncondition "HORN" switch ispushed "HORN" switch isnot pushed. o: Continuity 2.Voltage 0XX X0X X:Nocontinuity n GOOD '0 CONDITION 0 0 - ConnectthePocketTester(DC20V)tothe horn at the terminal. Tester(+)Lead-+BrownCDTerminal Tester(-) Lead-+Frame Ground 757 BAD CONDITION 1 "HORN" switchisfaulty. Replacehandlebar switch(Left). Check the horn voltage. Horn Voltage: 12.0V n MEETS "(7 SPECIFICATION 4.Horn Disconnectthe"Pink"leadatthehorn terminal. Connecta jumper leadCDto the horn termi-nalandgrundthe jumper lead. 5.Voltage HORNISNOT ... SOUNDED ConnectthePocketTester(DC20V)tothe horn at the Pink terminal. Tester (+)Lead~ PinkCDTerminal Tester(-) Lead~ Frame Ground Check the "Pink" terminal voltage. "Pink" TerminalVoltage: 12.0V n MEETS "(7 SPECIFICATION IAdjust or replacehorn. 7-58 SIGNAL SYSTEMIELEe IIii I OUT OFSPECIFICATION 3. Wiring connection Checktheentiresignalsystemfor connections.Refertothe"WIRING DIAGRAM" section. OUT OFSPECIFICATION IHornisgood . HORNISSOUNDED I Replacehorn. STARTINGFAILURE/HARD STARTINGISTHR.TBGLI?I ------------------------------------------------------TROUBLESHOOTING NOTE: ____________________________________________________________ Thefollowingtroubleshootingdoesnotcoverallthepossiblecausesof trouble.It shouldbehelpful, however,asa guidetotroubleshooting.Refertotherelativeprocedure inthis manual for inspection, adjustment andreplacement of parts. STARTINGFAILURE/HARD STARTING FUEL SYSTEMPROBABLE CAUSE Fueltank -------------------r- Empty L.Cloggedfuelfilter Cloggedfuelbreather pipe Deteriorated fuelor fuelcontaining water or foreignmaterial Fuelcock ------------------ Cloggedfuelhose Carburetor ---------------'""T-. Deterioratedfuel, fuelcontaining water or foreignmaterial Cloggedpi lot jet Cloggedpilot air passage Sucked-in air Deformed float Groove-worn needle valve Improperly sealedvalveseat Improperly adj ustedfuellevel .1 mproperly setpilot jet .Clogged starter jet Starter plunger malfunction Improperly adj ustedstarter cab Ie Air cleaner ------------------ Clogged Fuelpump ------------------. Faulty fuelpump STARTINGFAILURE/HARD STARTINGI J ~ ~ ?I ELECTRICAL SYSTEMPROBABLE CAUSE Sparkplug --------........- - Improper plug cap l-Worn electrodes -Wire between terminals broken - I mproper heat range - Faulty sparkplug cap Ignition COil----------..L--Broken or shortedprimary/secondary - Faulty sparkpluglead - Broken body Full-transistor system -----Lr-- - Faulty ignitor unit - Faulty pickup coil Switches andwiring -------..-- Faulty main switch - Faulty engine stop switch - Broken or shortedwiring - Faulty neutral switch - Faulty starter motor switch - Faulty clutch switch Starter motor -------...,..- - Faulty starter motor L-Faulty starter relay - Faulty circuit cut-off relay - Faulty starter clutch COMPRESSION SYSTEMPROBABLE CAUSE Cylinder andcylinder head L -Loose sprkplug -Loose cylinder heador cylinder -Broken cylinder headgasket -Worn, damagedor seizedcylinder Piston andpistonringsL-Improperly installedpistonring -Worn, fatiguedor brokenpiston ring -Seizedpistonring -Seized or damagedpiston Crankcase andcrankshaft ---r-- Improperly seatedcrankcase - Improperly sealedvalve - I mproperly contactedvalve andvalveseat - Improper valvetiming - Broken valve spring - Seizedcrankshaft 8-2 POORIDLE SPEED PERFORMANCE/ISTHRTBGLI?I POORMEDIUM AND HIGH SPEED PERFORMANCE___ POORIDLE SPEEDPERFORMANCE POORIDLE SPEED PERFORMANCEPROBABLECAUSE Carburetor ---------r- elmproperly returnedstarter plunger e Loosepilot jet eCloggedpilot air jet elmproperly adjustedidle speed (Throttle stop screw) e I mproper throttle cableplay e Floodedcarburetor Electricalsystem ------.,.- eFaulty battery e Faulty sparkplug e Faulty ignitor unit e Faulty pickup coil e Faulty ignition coil Valve train ---------elmproperly adjustedvalveclearance POORMEDIUM ANDHIGH SPEEDPERFORMANCE POORMEDIUM ANDHIGH SPEEDPERFORMANCE Refer to "Starting failure/Hardstarting." (Fuelsystem,electrical system, compressionsystem andvalve train) PROBABLE CAUSE Carburetor --------.,.L-el mproper jet need Ieclip position e Diaphragmmalfunction elmproperly adjustedfuellevel e Cloggedor loosemain jet Air cleaner ---------eCloggedair filter Fuelpump---------e Faulty fuelpump 8-3 _ __________ ISTHRTBGLI?I FAULTY GEAR SHI FTING... FAULTY GEAR SHIFTING HARD SHIFTING Refer to "Clutch dragging." SHIFT PEDAL DOESNOT MOVEPROBABLE CAUSE Shift shaft --------"PL--Improperl y adjustedshift rod -Bent shift shaft Shift cam,shift fork-------.L--Groove jammedwith impurities -Seized shift fork -Bent shift fork guide bar Transmission -------......- -Seizedtransmissiongear L -Jammedimpurities -I ncorrectly assembledtransmission JUMPOUT GEARPROBABLECAUSE Shift shaft --------.,.--Improperly adjusted L_lmproperly returnedstopper lever Shift fork---------- -Worn shift fork Shift cam --------.......L- -Improper thrust play -Worn shift camgroove Transmission--------- Worn gear dog 84 ISTHRTBGLI ?I CLUTCH SLIPPING/DRAGGING/OVERHEATING_ ----------------------------------------------------------CLUTCH SLIPPING/DRAGGING CLUTCH SLIPPINGPROBABLE CAUSE Clutch --------------------T- -Loose clutch spring L-Fatiguedclutch spring -Worn frictionplate/clutchplate Engineoil - - - - - - - - - - - - - - - ~ , - - - Low oillevel L-Improper quality/viscosity CLUTCHDRAGGINGPROBABLE CAUSE Clutch-------------------.,...- -Warpedpressureplate, air-containedclutch fluid - Unevenly tensionedclutch springs - Matchmarks not aligned - Bent pushrod - Loosepushrod/bent clutch bossnut - Burnt primary drivengearbushing - Bent clutch plate Engine oil------------------...--Improper oillevel L -Improper quality/viscosity - Deterioration OVERHEATING OVERHEATINGPROBABLE CAUSE Ignition system -------------r- -I mproper sparkplug gap L -I mproper sparkplugheatrange - Faulty ignitor unit Fuelsystem ----------------""L--Improper carburetor main jet (setting) -Improperly adjustedH dimension -Clogged air filter Compressionsystem -------Heavy carbon buld-up Engine oil-----------------,---Incorrect oillevel L -I mproper oil viscosity -Inferior oil quality Brake ---------------------- - D raggingbrake 8-5 FAULTV BRAKE/FRONT FORK 01 LLEAKAGEISTHRTBG LI ?I ANDFRONTFORKMALFUNCTION___ FAULTV BRAKE POORBRAKINGEFFECTPROBABLE CAUSE Disc brake --------r--Wornbrake pads -Worn disc -Air in brake fluid - Leaking brake fluid - Faulty cylinder kit cup - Faulty caliper kit seal - Loose union bolt - Broken brakehose - Oily or greasy disc/brake pads - I mproper brake fluidlevel Drum brake --------....,..- -Worn brake shoe -Worn or rusty brake drum -I mproperly adjustedbrake free play -I mproper brake camlever position -I mproper brake shoeposition -Fatigue/Damagedreturnspring -Oily or greasybrake shoe -Oil or greasybrake drum -Broken brake cable FRONT FORK OIL LEAKAGE AND FRONTFORK MALFUNCTION OIL LEAKAGEPROBABLE CAUSE I----------------r--Bent, damagedor rustyinner tube -Damaged or crackedouter tube -Damagedoil seallip -Improperly installed oil seal -Improper oillevel(too much) - Loose damper rodholding bolt -Broken capbolt O-ring MALFUNCTIONPROBABLE CAUSE I---------------"T"""-Bent, deformed or damagedinner tube -Bent or deformed outer tube -Damagedfork spring -Worn or damagedslide metal -Improper oil viscosity -Improper oillevel 8-6 INSTABLE HANDLING ?I INSTABLE HANDLING INSTABLE HANDLINGPROBABLE CAUSE Handlebar-----------elmproperly installedor bent steering-----------..,lr-e Improperlyinstalledhandlebar crown eBent steering stem el mproperlyinstalledsteering shaft (I mproperly tightenedri ngnut) eDamagedballbearing or bearingrace Front forks oillevels onboth sides eBroken spring eTwisted front forks Tirestirepressures onboth sides el ncorrect ti repressu re eUnevenly worntires Wheels ____________-el ncorrect wheelbalance eDeformedspoke wheel eDamagedbearing eBent or loose wheelaxle eExcessive wheelrun-out e Loosedspoke Frame ------------r-eTwisted LeDamagedheadpipe el mproperlyinstalledbearingrace Swingarm -----------L-eWornbearing or bush eBent or damaged Rear shock absorber------_L-eFatigued spring eOilleakage Drive chain-----------elmproperly adjustedchainslack 8-7 FAULTY SIGNAL ANDLIGHTING SYSTEM ISTHRTBGLI ?I - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ ~ ~ ~ - - - - ~FAULTY SIGNAL AND LIGHTING SYSTEM HEADLIGHT DARKPROBABLE CAUSE L-_____________-,-- e I mproper bulb e Too many electric accessories e Hardcharging(brokenstator coil wire, faulty rectifier with regulator) elncorrect connection e I mproperly grounded e Poor contacts(main or light switch) e Bulblife expires BULB BURNT OUTPROBABLE CAUSE L.I-------------_-elmproper bulb LelmproperlY grounded FLASHERDOES NOT LIGHT eFaulty main and/orlight switch eBulblife expires PROBABLE CAUSE L....______________ el mproperly grounded eDischargedbattery eFaulty flasherswitch eFaulty flasherrelay eBroken wireharness e Loosely connectedcoupler eBulb burnt out eFaulty fuse FLASHERKEEPS ONPROBABLE CAUSE 1L..---------------r-eFaulty flasherrelay lei nsufficient battery capacity (nearly discharged) eBulb burnt out 8-8 ______________O_V_ER_H_E_A_T_IN_G ?I FLASHER WINKS SLOWERPROBABLE CAUSE ""'----------------r-e F au Ity flasherrelay el nsufficient battery capacity (nearly discharged) elmproper bulb eFaulty main and/or "TURN" switch FLASHER WINKS QUICKERPROBABLE CAUSE L"I--------------..,r-elmproper bulb LeFaulty flasherrelay HORNISINOPERATIVE (Except for Holland)PROBABLE CAUSE Fau Ity battery OVERHEATING eFaulty fuse eFaulty mainand/or hornswitch el mproperly adjustedhorn eFaulty horn eBroken wireharness OVERHEATINGPROBABLE CAUSE Ignition system--------'T-elmproper sparkplug gap Lelmproper sparkplug heat range elmproper ignition timing Fuelsystem---------""-elmproper carburetor main jet l (I mproper setting) eCloggedair cleanerelement eLeanmixture (Faulty Autolube pump settings) Compressionsystem -------eHeavy carbonbuild-up Transmissionoil-------__,.-elncorrect, oillevel Lei mproper oil viscosity elnferior oil quality Brake -------------eDragging brake 8-9 XV250U/XV250UC WIRINGDIAGRAM "START" switchi