YFM250BT

SUPPLEMENTARY

SERVICE MANUAL

LIT-11616-18-41 4XE-F8197-13

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

YFM250BT. For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

YFM250XL(C) SERVICE MANUAL: LIT-11616-12-01 (4XE-F8197-10)

YFM250XN SUPPLEMENTARY SERVICE MANUAL: LIT-11616-14-17 (4XE-F8197-11)

YFM250XP SUPPLEMENTARY SERVICE MANUAL: LIT-11616-15-03 (4XE-F8197-12)

YFM250BT

SUPPLEMENTARY

SERVICE MANUAL

©2004 by Yamaha Motor Corporation, U.S.A.

First edition, July 2004

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.

LIT-11616-18-41

EBS00002

NOTICE

This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on

Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all 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:

Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

WARNING

CAUTION:

NOTE:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person checking or repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

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

EBS00004

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “symbols”)

1st title

1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title

2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.

3rd title

3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1. An easy-to-see exploded diagram

4 is provided for removal and disassembly jobs.

2. Numbers

5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6. The meanings of the symbol marks are given on the next page.

4. A job instruction chart

7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements

8 are given in addition to the exploded diagram and the job instruction chart.

1

3

GEN

INFO

5

CHK

ADJ

CARB

7

CHAS

9

A

TRBL

SHTG

2

SPEC

4

6

ENG

8

DRIV

ELEC –

0

+

EBS00005

SYMBOLS

The following symbols are not relevant to every machine.

Symbols

1 to 9 indicate the subject of each chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Engine

5 Carburetion

6 Drive train

7 Chassis

8 Electrical

9 Troubleshooting

C

B

D

Symbols

0 to F indicate the following.

0 Filling fluid

A Lubricant

B Special tool

C Torque

D Wear limit, clearance

E Engine speed

F Electrical data (Ω, V, A)

.

T

R

.

E F

G H I

J

B

E

K

LS

G

L

M

M

M

S

N O

New

LT

Symbols

G to M in the exploded diagrams indicate the types of lubricants and lubrication points.

G Apply engine oil

H Apply gear oil

I Apply molybdenum disulfide oil

J Apply wheel bearing grease

K Apply lithium-soap-based grease

L Apply molybdenum disulfide grease

M Apply silicon grease

Symbols N to O in the exploded diagrams indicate where to apply a locking agent N and when to install a new part O.

N Apply the locking agent (LOCTITE ®

O Replace

)

CONTENTS

SPECIFICATIONS .............................................................................................1

GENERAL SPECIFICATIONS ....................................................................1

MAINTENANCE SPECIFICATIONS ...........................................................2

ENGINE ................................................................................................2

CHASSIS ..............................................................................................3

ELECTRICAL ........................................................................................4

CABLE ROUTING .......................................................................................5

PERIODIC CHECKS AND ADJUSTMENTS ...................................................14

INTRODUCTION .......................................................................................14

PERIODIC MAINTENANCE/LUBRICATION .............................................14

SEAT, CARRIERS, FENDERS AND FUEL TANK ....................................16

SEAT, FRONT CARRIER, FRONT BUMPER

AND FRONT FENDER ......................................................................16

REAR CARRIER AND REAR FENDER ..............................................18

FUEL TANK ........................................................................................20

FOOTREST BOARDS ...............................................................................21

ENGINE .....................................................................................................22

ADJUSTING THE STARTER CABLE .................................................22

CHASSIS ...................................................................................................23

ADJUSTING THE REAR BRAKE .......................................................23

ADJUSTING THE SELECT LEVER CONTROL CABLE

AND SHIFT ROD ...............................................................................25

ADJUSTING THE HEADLIGHT BEAM ...............................................26

REPLACING A HEADLIGHT BULB ....................................................26

ENGINE ...........................................................................................................28

ENGINE REMOVAL ..................................................................................28

SELECT LEVER ASSEMBLY .............................................................28

CARBURETION ...............................................................................................29

CARBURETOR .........................................................................................29

CHASSIS .........................................................................................................32

REAR BRAKE ...........................................................................................32

STEERING SYSTEM ................................................................................34

STEERING STEM ...............................................................................34

REMOVING THE REAR BRAKE SWITCH .........................................36

INSTALLING THE HANDLEBAR ........................................................36

ELECTRICAL ..................................................................................................37

ELECTRICAL COMPONENTS ..................................................................37

YFM250BT WIRING DIAGRAM

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Model code:

Dimensions:

Overall length

Overall width

Overall height

Seat height

Wheelbase

Minimum ground clearance

Minimum turning radius

Basic weight:

With oil and full fuel tank

Carburetor:

Type/quantity

Manufacturer

Tire:

Type

Size

Manufacturer front rear front

Type rear front rear

Electrical:

Ignition system

Generator system

Battery type

Battery capacity

Bulb wattage

× quantity:

Headlight

Tail/brake light

Indicator lights:

Neutral

Reverse

1P01

1,916 mm (75.4 in)

1,038 mm (40.9 in)

1,118 mm (44.0 in)

772 mm (30.4 in)

1,170 mm (46.1 in)

150 mm (5.9 in)

2,900 mm (114 in)

216 kg (476 lb)

BSR33/1

MIKUNI

Tubeless

AT22

× 7-10

AT22

× 10-10

MAXXIS

MAXXIS

M905

M906

DC C.D.I.

A.C. magneto

CB14A-A2

12 V 14 AH

Standard

12 V 30 W/30 W

× 2

12 V 5 W/21 W

× 1

12 V 1.7 W

× 1

12 V 1.7 W

× 1

SPEC

– 1 –

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Carburetor:

I. D. mark

Main jet

Main air jet

Jet needle

Needle jet

Pilot air jet

Pilot air jet

Pilot outlet

Pilot jet

Bypass 1

Bypass 2

Bypass 3

Valve seat size

Starter jet

Starter jet

Throttle valve size

Float height

Fuel level

Engine idle speed

Intake vacuum

Item

Tightening torques

Standard

(M.J)

(M.A.J)

(J.N)

(N.J)

1P01 00

#93.8

#70

5EP17-2

P-2M (826)

(P.A.J.1) #80

(P.A.J.2) 1.3

(P.O)

(P.J)

(B.P.1)

(B.P.2)

(B.P.3)

(V.S)

(G.S.1)

(G.S.2)

(Th.V)

(F.H)

(F.L)

0.8

#20

0.8

0.8

0.8

2.0

#62.5

0.9

#100 ----

12.0 ~ 14.0 mm (0.47 ~ 0.55 in) ----

4.0 ~ 5.0 mm (0.16 ~ 0.20 in)

1,400 ~ 1,500 r/min

----

----

30.7 kPa (230 mmHg, 9.06 inHg) ----

----

----

----

----

----

----

----

----

----

----

----

----

----

----

----

Limit

Part to be tightened

Starter motor holding bracket

Bearing retainer 1

(bearing housing)

Drive select lever unit and frame

Drive select lever component:

Lever component

Middle drive pinion gear

Shift guide stopper bolt

Part name

Screw

Nut

Bolt

Bolt

Nut

Bolt

Thread size

Q’ty

M6 2

M50

M8

1

2

M6

M16

M8

1

1

1

Tightening torque

Nm m · kg ft · lb

7 0.7

5.1

80 8.0

58

23 2.3

17

Remarks

14 1.4

10

90 9.0

65 Stake

20 2.0

14

LT

– 2 –

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS

Item

Brake lever and brake pedal:

Front brake lever free play (at lever pivot)

Rear brake lever free play (at lever pivot)

Brake pedal free play

Throttle lever free play

Tightening torques

Part to be tightened

Steering knuckle and tie-rod end

Tie-rod and locknut

Steering shaft and tie-rod end

Front carrier and frame

Front carrier and front fender

Front carrier and front bumper

Front bumper and frame

Front bumper, front fender and front grill

Front fender and front grill

Rear carrier and frame

Rear carrier and rear fender

Rear fender, air filter case and frame

Rear fender and frame

Battery holding bracket

Footrest bracket and frame

(left and right)

Footrest, footrest board and footrest bracket (left and right)

0 mm (0 in)

Standard

5 ~ 7 mm (0.20 ~ 0.28 in)

20 ~ 30 mm (0.79 ~ 1.18 in)

3 ~ 5 mm (0.12 ~ 0.20 in)

Part name

Thread size Q’ty

Nut M12

× 1.25

2

Nut M12

× 1.25

4

Nut M12

× 1.25

2

Bolt M8

× 1.25

4

Bolt M6

× 1.0

2

Bolt M8

× 1.25

2

Bolt M8

× 1.25

4

Bolt

Bolt M6

× 1.0

2

Bolt M8

× 1.25

4

Bolt M6

× 1.0

2

Bolt

M6

× 1.0

M6

× 1.0

2

2

Bolt

Bolt

M6

× 1.0

M6 × 1.0

1

2

Bolt M10

× 1.25

4

Bolt M8

× 1.25

4

Bolt M6

× 1.0

4

7

7

7

Tightening torque

Nm m · kg ft · lb

30 3.0

22

40 4.0

29

30 3.0

22

34 3.4

24

7 0.7

5.1

34 3.4

24

34 3.4

24

7 0.7

5.1

7 0.7

5.1

34 3.4

24

7 0.7

5.1

0.7

5.1

0.7

5.1

0.7

5.1

65 6.5

47

34 3.4

24

7 0.7

5.1

----

----

----

----

Limit

Remarks

– 3 –

ELECTRICAL

Item

C.D.I.:

Magneto model/manufacturer

Pickup coil resistance/color

Rotor rotation direction detection coil resistance/color

C.D.I. unit model/manufacturer

Electric starter system:

Type

Starter motor:

Model/manufacturer

Output

Armature coil resistance

Brush overall length

MAINTENANCE SPECIFICATIONS

Standard

F4T259/MITSUBISHI

189 ~ 231

Ω at 20 °C (68 °F)/

White/Green – White/Red

0.065 ~ 0.080

Ω at 20 °C (68 °F)/

Red – White/Blue

F8T38683/MITSUBISHI

----

----

----

----

Constant mesh type

5XG/MORIC TAIWAN

0.4 kW

0.0144 ~ 0.0176

Ω at 20 °C

(68 °F)

10 mm (0.4 in)

----

----

----

----

Spring force

Commutator diameter

Mica undercut

Starter relay:

Model/manufacturer

Amperage rating

Coil winding resistance/color

563 ~ 844 g (5.52 ~ 8.28 N)

22 mm (0.87 in)

1.5 mm (0.059 in)

MS5F-721/JIDECO

180 A

4.2 ~ 4.6

Ω at 20 °C (68 °F)/

Blue/Black – Blue/White

SPEC

----

----

----

Limit

3.5 mm

(0.14 in)

----

21 mm

(0.83 in)

----

– 4 –

CABLE ROUTING

1 Rear brake light switch lead

2 Starter cable

3 Rear brake cable

4 Lower bracket cable guide

5 Front brake hose

6 Front brake light switch lead

7 Throttle cable

8 Reverse indicator light

9 Neutral indicator light

CABLE ROUTING

SPEC

0 Fuel tank breather hose

A Handlebar switch assembly lead

B Rectifier/regulator

– 5 –

È Do not route the handlebar switch assembly lead through the lower bracket cable guide.

É Fasten the front brake light switch lead to the handlebar with the plastic band.

Ê Faster the front brake light switch lead and front brake hose to the handlebar with the plastic band.

Ë Route the fuel tank breather hose through the hole in the handlebar cover and then to the right of the handlebar (below the handlebar, not over it). Then, pass the hose through the cable guide.

CABLE ROUTING

SPEC

Ì Fasten the handlebar switch assembly lead, rear brake light switch lead, and starter cable to the handlebar with the plastic bands.

Í Fasten the handlebar switch assembly lead to the handlebar with the plastic band.

Î Fasten the rear brake light switch lead, front brake light switch lead, and handlebar switch assembly lead with the plastic band.

Ï Fasten the headlight leads to the frame with the clamp.

– 6 –

1 Headlight lead

2 Lower bracket cable guide

3 Indicator light lead

4 Main switch lead

5 Indicator light

6 Main switch

7 Fuel tank breather hose

8 Carburetor overflow hose

9 Reverse switch lead

0 Neutral switch lead

CABLE ROUTING

A Negative battery lead

B A.C. magneto lead

C Starter cable

D Rear brake cable

E Select lever control cable

F Throttle cable

G Starter motor lead

SPEC

– 7 –

È Fasten the headlight lead to the front bumper with the plastic band.

É Route the main switch lead and indicator light lead to the side of the lower bracket cable guide.

Ê Fasten the starter cable to the frame with the plastic locking tie.

Ë Insert the carburetor air vent hose, rear brake breather hose, and final gear case breather hose into the air duct after routing them through the fuel tank grommet.

CABLE ROUTING

SPEC

Ì Route the carburetor overflow hose between the engine and upper rear engine mount and then between the engine and swingarm. Make sure that the hose is not pinched.

Í Route the reverse switch lead and neutral switch lead to the right of the rear arm boot.

Î Fasten the starter motor lead to the frame with the plastic clamp. Route the starter motor lead over the throttle cable and rear brake cable.

Ï Bend the cable guide after routing the cables.

– 8 –

1 A.C. magneto lead couplers

2 Wire harness

3 Starter motor lead

4 Tail/brake light lead

5 Battery breather hose

6 Final gear case breather hose

7 Negative battery lead

8 Ground lead

9 Carburetor air vent hose

0 Rear brake breather hose

CABLE ROUTING

SPEC

A Rear brake light switch lead

B Rear brake cable

C A.C. magneto lead

È Make sure that the starter motor lead has no slack.

É 0 mm (0 in)

Ê Fasten the starter motor lead and wire harness to the frame with the plastic band.

– 9 –

Ë Fasten the negative battery lead with the plastic clamp.

Ì Fasten the tail/brake light lead and negative battery lead with the plastic locking tie.

Í Fasten the negative battery lead with the plastic clamp.

Î 40 ~ 50 mm (1.6 ~ 2.0 in)

Ï Fasten the starter motor lead and wire harness to the frame with the plastic clamp.

Ð Route the rear brake cable and rear brake breather hose through the cable guide.

CABLE ROUTING

SPEC

Ñ 100 mm (4.0 in)

Ò Route the rear brake breather hose through the cable guide.

Ó Route the final gear case breather hose through the cable guide.

Ô Fasten the rear brake cable and rear brake breather hose to the swingarm with the plastic clips.

– 10 –

1 Battery breather hose

2 Rear brake cable

3 Select lever control cable

4 Spark plug cap

5 Ignition coil

6 Ignition coil leads

7 Starter motor lead

8 Rear brake light switch

9 Rear brake breather hose

CABLE ROUTING

SPEC

È Fasten the battery breather hose to the frame with the plastic band.

É Fasten the starter motor lead to the frame with the plastic clamps.

Ê 50 ~ 60 mm (2.0 ~ 2.4 in)

Ë Fasten the battery breather hose to the frame with the plastic clamps.

– 11 –

1 Positive battery lead

2 Battery

3 Tail/brake light lead

4 Negative battery lead

5 CDI unit

6 Starter relay

7 Wire harness

8 Starter motor lead

9 Carburetor air vent hose

0 Final gear case breather hose

A Rear brake breather hose

CABLE ROUTING

SPEC

È Fasten the wire harness, starter motor lead, and select lever control cable to the frame with the plastic band.

É 5 mm (0.2 in)

Ê Fasten the positive battery lead to the rear fender with the plastic clamps.

Ë Make sure that the grommet is installed with the mark facing forward.

– 12 –

1 Headlight leads

2 Wire harness

3 Starter motor lead

4 Rear brake cable

5 Throttle cable

6 Starter cable

7 Select lever control cable

8 Rectifier/regulator

È Fasten the wire harness to the frame with the plastic clamps.

CABLE ROUTING

SPEC

É Make sure the starter motor lead and wire harness do not contact the ignition coil.

Ê 50 mm (2.0 in)

Ë Route the throttle cable, select lever control cable and rear brake cable through the cable guide. Make sure that the throttle cable is routed to the inside of the rear brake cable.

Ì Fasten the wire harness, starter motor lead, and ignition coil lead to the frame with the plastic band.

– 13 –

INTRODUCTION/

PERIODIC MAINTENANCE/LUBRICATION

CHK

ADJ

EB300000

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and adjustments.

These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION

NOTE:

• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.

• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.

ITEM ROUTINE

Whichever comes first

Valves*

Spark plug

Air filter element

Carburetor*

Cylinder head breather system*

Exhaust system*

Spark arrester

Fuel line*

Engine oil

Engine oil filter element

Engine oil strainer

Final gear oil

Front brake*

Rear brake*

Select lever safety system cable*

Clutch*

• Check valve clearance.

• Adjust if necessary.

• Check condition.

• Adjust gap and clean.

• Replace if necessary.

• Clean.

• Replace if necessary.

• Check starter (choke).

• Adjust engine idling speed.

• Check breather hose for cracks or damage.

• Replace if necessary.

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

• Clean.

• Check fuel hose for cracks or damage.

• Replace if necessary.

• Replace (Warm engine before draining).

• Clean.

• Clean.

• Check oil level/oil leakage.

• Replace.

• Check operation/fluid leakage/see NOTE page 15.

• Correct if necessary.

• Check operation.

• Adjust if necessary.

• Check operation.

• Adjust if necessary.

• Check operation.

• Adjust if necessary.

month km

(mi) hours

1

320

(200)

20

INITIAL

3

1,200

(750)

75

6

2,400

(1,500)

150

EVERY

6

2,400

(1,500)

150

12

4,800

(3,000)

300

Every 20–40 hours

(more often in wet or dusty areas)

– 14 –

PERIODIC MAINTENANCE/LUBRICATION

CHK

ADJ

Wheels*

ITEM

Wheel bearings*

Front and rear suspension*

Steering system*

ROUTINE

Whichever comes first

• Check balance/damage/runout.

• Repair if necessary.

• Check bearing assemblies for looseness/damage.

• Replace if damaged.

• Check operation.

• Correct if necessary.

• Check operation./Replace if damaged.

• Check toe-in./Adjust if necessary.

month km

(mi) hours

Steering shaft*

Fittings and fasteners*

• Lubricate every 6 months with lithium-soap-based grease (all-purpose grease).

• Check all chassis fittings and fasteners.

• Correct if necessary.

Battery*

• Check specific gravity.

• Check that the breather hose is working properly.

• Correct if necessary.

Lights and switches*

• Check operation.

• Adjust headlight beams.

1

320

(200)

20

INITIAL

3

1,200

(750)

75

6

2,400

(1,500)

150

EVERY

6

2,400

(1,500)

150

12

4,800

(3,000)

300

* It is recommended that these items be serviced by a Yamaha dealer.

NOTE:

• Recommended brake fluid: DOT 4

• Brake fluid replacement:

1. When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and add fluid as required.

2. On the inner parts of the master cylinder and caliper, replace the oil seals every two years.

3. Replace the brake hoses every four years, or if cracked or damaged.

WARNING

Indicates a potential hazard that could result in serious injury or death.

– 15 –

SEAT, CARRIERS, FENDERS AND FUEL TANK

SEAT, CARRIERS, FENDERS AND FUEL TANK

SEAT, FRONT CARRIER, FRONT BUMPER AND FRONT FENDER

CHK

ADJ

T

R

34 Nm (3.4 m

•

kg, 24 ft

•

Ib)

2

9

7

10

1

T

R

7 Nm (0.7 m •

kg, 5.1 ft

• Ib)

8

11

(6)

T

R

7 Nm (0.7 m

•

kg, 5.1 ft

•

Ib)

5

T

R

34 Nm (3.4 m •

kg, 24 ft

• Ib)

6

(6)

4

3 T

R

7 Nm (0.7 m •

kg, 5.1 ft

• Ib)

T

R

34 Nm (3.4 m

•

kg, 24 ft

•

Ib)

Order

1

Job/Part

Removing the seat, front carrier, front bumper and front fender

Seat

2

3

4

5

6

7

8

9

Front carrier

Engine skid plate

Front bumper

Headlight coupler

Front grill

Main switch coupler

Indicator light coupler

Handlebar cover

10 Fuel tank cover

Q’ty Remarks

Remove the parts in the order listed.

1

NOTE:

Pull up the seat lock lever, then pull up on the rear of the seat.

1

1

1

2 Disconnect.

1

1 Disconnect.

1 Disconnect.

1

1

– 16 –

SEAT, CARRIERS, FENDERS AND FUEL TANK

CHK

ADJ

T

R

7 Nm (0.7 m •

kg, 5.1 ft

• Ib)

T

R

34 Nm (3.4 m

•

kg, 24 ft

•

Ib)

2

9

7

8

11

(6)

5

10

1

T

R

7 Nm (0.7 m

•

kg, 5.1 ft

•

Ib)

T

R

34 Nm (3.4 m •

kg, 24 ft

• Ib)

(6)

6

4

3 T

R

7 Nm (0.7 m •

kg, 5.1 ft

• Ib)

T

R

34 Nm (3.4 m

•

kg, 24 ft

•

Ib)

Order

11 Front fender

Job/Part Q’ty

1

Remarks

For installation, reverse the removal procedure.

– 17 –

SEAT, CARRIERS, FENDERS AND FUEL TANK

CHK

ADJ

REAR CARRIER AND REAR FENDER

T

R

34 Nm (3.4 m

•

kg, 24 ft

•

Ib)

3

2

T

R

7 Nm (0.7 m •

kg, 5.1 ft

• Ib)

T

R

34 Nm (3.4 m

•

kg, 24 ft

•

Ib)

1

T

R

7 Nm (0.7 m

•

kg, 5.1 ft

•

Ib)

4 4

12

14

5

6

11

10

7

8

13

9 15

(6)

(6)

T

R

7 Nm (0.7 m •

kg, 5.1 ft

• Ib)

Order Job/Part

Removing the rear carrier and rear fender

Seat and fuel tank cover

Q’ty Remarks

Remove the parts in the order listed.

1

2

3

4

5

6

7

Rear carrier

Battery cover

Battery holding bracket

Battery lead

Battery

Battery breather hose

CDI unit coupler

Refer to “SEAT, FRONT CARRIER,

FRONT BUMPER AND FRONT

FENDER”.

1

1

1

2 Disconnect.

CAUTION:

First disconnect the negative lead, then disconnect the positive lead.

1

1 Disconnect.

1 Disconnect.

– 18 –

SEAT, CARRIERS, FENDERS AND FUEL TANK

CHK

ADJ

4

5

6

3

2

T

R

7 Nm (0.7 m •

kg, 5.1 ft

• Ib)

T

R

34 Nm (3.4 m

•

kg, 24 ft

•

Ib)

1

T

R

7 Nm (0.7 m

•

kg, 5.1 ft

•

Ib)

T

R

34 Nm (3.4 m

•

kg, 24 ft

•

Ib)

4

11

10

13

12

14

7

8

9 15

(6)

(6)

T

R

7 Nm (0.7 m •

kg, 5.1 ft

• Ib)

Order

8 CDI unit

Job/Part

9 Tail/brake light connector

10 Starter relay coupler

11 Starter motor lead

12 Starter relay

13 Starting circuit cut-off relay coupler

14 Starting circuit cut-off relay

15 Rear fender

Q’ty

1

3 Disconnect.

1 Disconnect.

1 Disconnect.

1

Remarks

1 Disconnect.

1

1

For installation, reverse the removal procedure.

– 19 –

FUEL TANK

SEAT, CARRIERS, FENDERS AND FUEL TANK

CHK

ADJ

T

R

10 Nm (1.0 m

•

kg, 7.2 ft

•

Ib)

T

R

10 Nm (1.0 m

•

kg, 7.2 ft

•

Ib)

2

1

Order Job/Part

Removing the fuel tank

Seat and fuel tank cover

1 Fuel hose

2 Fuel tank

Q’ty

1

Remarks

Remove the parts in the order listed.

Refer to “SEAT, FRONT CARRIER,

FRONT BUMPER AND FRONT

FENDER”.

NOTE:

Before disconnecting the fuel hose, turn the fuel cock to “OFF”.

1

NOTE:

When installing the fuel tank, pass the fuel tank breather hose through the hole of the handlebar cover.

For installation, reverse the removal procedure.

– 20 –

FOOTREST BOARDS

T

R

7 Nm (0.7 m

•

kg, 5.1 ft

•

Ib)

1

FOOTREST BOARDS

CHK

ADJ

T

R

65 Nm (6.5 m •

kg, 47 ft

• Ib)

T

R

7 Nm (0.7 m •

kg, 5.1 ft

• Ib)

3

5

(12)

1

(12)

T

R

34 Nm (3.4 m

•

kg, 24 ft

•

Ib)

3

4

1

2

5

Order Job/Part

Removing the footrest boards

Footrest

Left footrest board

Right footrest board

Left footrest bracket

Right footrest bracket

4

2

T

R

65 Nm (6.5 m

•

kg, 47 ft

•

Ib)

Q’ty Remarks

Remove the parts in the order listed.

1

1

2

1

1

For installation, reverse the removal procedure.

– 21 –

ADJUSTING THE STARTER CABLE

1

CHK

ADJ

ENGINE

ADJUSTING THE STARTER CABLE

1. Adjust:

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the starter cable

1 from the carburetor body.

NOTE:

Do not remove the starter plunger

2 from the starter cable.

b. Measure the starter plunger stroke distance a of the starter lever 3 fully close to fully open position. If the distance is out of specification adjust it as described below.

Starter plunger stroke distance

15 mm (0.59 in)

È

Fully closed position

É

Fully open position c. Pull back the boot

4.

d. Loosen the locknut

5.

e. Turn the adjusting nut

6 in or out until the correct free play is obtained.

Turning in Free play increased.

Turning out Free play decreased.

f. Tighten the locknut

5.

g. Push in the boot

4.

h. Connect the starter cable to the carburetor.

WARNING

After adjusting the cable, turn the handlebar to right and left, and make sure that the engine idling speed does not increase.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

– 22 –

ADJUSTING THE REAR BRAKE

CHK

ADJ

CHASSIS

ADJUSTING THE REAR BRAKE

WARNING

Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake.

1. Remove:

• right footrest board

Refer to “FOOTREST BOARDS”.

2. Check:

• brake pedal height a

• brake pedal free play b

• rear brake lever free play c

Out of specification → Adjust.

Brake pedal height

43 ~ 53 mm (1.69 ~ 2.09 in)

Brake pedal free play

20 ~ 30 mm (0.79 ~ 1.18 in)

Rear brake lever free play

5 ~ 7 mm (0.20 ~ 0.28 in)

3. Adjust:

• brake pedal height

• brake pedal free play

• rear brake lever free play

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknuts

1.

b. Turn the adjusting bolt

2 until the brake pedal height is within the specified limits.

c. Tighten the locknuts.

– 23 –

ADJUSTING THE REAR BRAKE

CHK

ADJ d. Loosen the locknut

3 and fully screw in the brake lever cable adjusting bolt

4.

e. Fully loosen the brake lever cable adjusting nut

5.

f. Turn the brake pedal adjusting nut

6 until the brake pedal free play is within the specified limits.

g. Turn the brake lever cable adjusting nut 5 clockwise until the gap a is within the specified limits.

Gap

0 ~ 1 mm (0 ~ 0.04 in) h. Checking the brake pedal free play to see whether or not it is within the specified limits. If not, perform the above steps again.

i. Turn the brake lever cable adjusting nut

4 until the rear brake lever free play is within the specified limits.

j. Tighten the locknut

3.

k. Adjust the select lever control cable.

Refer to “ADJUSTING THE SELECT

LEVER CONTROL CABLE AND SHIFT

ROD”.

WARNING

After this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed perform the above steps again.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

– 24 –

ADJUSTING THE SELECT LEVER CONTROL CABLE

AND SHIFT ROD

1

2

CHK

ADJ

ADJUSTING THE SELECT LEVER

CONTROL CABLE AND SHIFT ROD

1 FORWARD

2 REVERSE

3 Control cable

4 Select lever shift rod

WARNING

Before moving the select lever, bring the machine to a complete stop and return the throttle lever to its closed position. Otherwise the transmission may be damaged.

3

4 1. Adjust:

• brake pedal free play

Refer to “ADJUSTING THE REAR BRAKE”.

2

1

2. Adjust:

• select lever control cable

• select lever shift rod

▼ ▼▼▼ ▼ ▼▼▼ ▼

Control cable:

▼ ▼▼▼ ▼ ▼▼▼ a. Make sure the select lever is in FORWARD.

b. Adjust the control cable so there is zero free play in the cable. When the adjustment is correct, slack in the return spring

1 will be taken up.

NOTE:

In some cases it will be necessary to further adjust the cable with the locknuts

2 arrangement that holds the cable to its mount. c. When the brake begins to work “ a = 20 ~

30 mm (0.79 ~ 1.18 in)”, verify that the select lever can be shifted to REVERSE from FORWARD and to FORWARD from

REVERSE.

d. Before the brake begins to work “ a = 0 ~

20 mm (0 ~ 1.18 in)”, verify that the select lever cannot be shifted to REVERSE from

FORWARD and to FORWARD from

REVERSE.

– 25 –

1

ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT

ROD/ADJUSTING THE HEADLIGHT BEAM/

REPLACING A HEADLIGHT BULB

3

4

2

CHK

ADJ e. Check that locknuts

2 are tightened correctly.

f. If the operation of the select lever is incorrect, adjust the select lever control cable

3 with the adjuster

4.

3

4

2

Select lever shift rod: a. Make sure the select lever

1 is in FOR-

WARD.

b. Loosen the locknuts

2.

c. Turn the select lever adjusting nut

3 in or out until lever

4 center line a aligns with match mark b on the crankcase cover.

d. Tighten the locknuts

2.

T

.

R

.

Locknut (select lever adjuster)

15 Nm (1.5 m · kg, 11 ft · lb)

NOTE:

After adjusting the drive select lever, be sure the reverse indicator light comes on when the drive select lever is in reverse position.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

ADJUSTING THE HEADLIGHT BEAM

1. Adjust:

• headlight beam (vertically)

Turn the adjusting screw

1 in or out.

Turning in

Turning out

Headlight beam raised.

Headlight beam lowered.

REPLACING A HEADLIGHT BULB

1. Remove:

• cover

1

– 26 –

REPLACING A HEADLIGHT BULB

2. Remove:

• bulb holder

1

• bulb

CHK

ADJ

NOTE:

Turn the bulb holder counterclockwise and remove the defective bulb by unhooking the headlight bulb holder tabs

2.

WARNING

Keep flammable products and your hands away from the bulb while it is on, since it will be hot. Do not touch the bulb until it cools down.

3. Install:

• bulb

New

Secure the new bulb with the headlight unit.

CAUTION:

Avoid touching the glass part of the bulb.

Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

4. Install:

• bulb holder

• cover

– 27 –