YFM350R-W N0A1-AE1

SUPPLEMENTARY
SERVICE MANUAL
 FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the
YFM350R-W. For complete service information procedures it is necessary to use this Supplemen-
tary Service Manual together with the following manual.

YFM350X(J) ’97 SERVICE MANUAL: 3GD-AE5

YFM350X(P) 2002 SUPPLEMENTARY SERVICE MANUAL: 3GD-AE6
YFM350S SUPPLEMENTARY SERVICE MANUAL: 3GD-AE7

YFM350R-W
SUPPLEMENTARY
SERVICE MANUAL
©2005 by MBK Industrie
First edition, April 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
MBK Industrie
is expressly prohibited.
EBS00002

NOTICE
This manual was produced by MBK industrie 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 sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.

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.
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 machine operator, a bystander or a person checking or repairing the
machine.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid dam-
age to the machine.
NOTE: 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 accompa-
nied 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.
 EB003000
1 2 ILLUSTRATED SYMBOLS
GEN Illustrated symbols 1 to 8 are printed on the

INFO SPEC top right of each page and indicate the subject
of each chapter.
3 4
1 General information
2 Specifications
CHK 3 Periodic checks and adjustments
ADJ ENG 4 Engine
5 Carburetion
5 6 6 Chassis
7 Electrical
8 Troubleshooting
CARB CHAS
7 8

ELEC – + TRBL
SHTG
9 0 Illustrated symbols 9 to E are used to identify
the specifications appearing in the text.
9 Filling fluid
0 Lubricant
A Special tool
A B B Torque
C Wear limit, clearance
D Engine speed
T.
R.

E Ω, V, A

C D

Illustrated symbols F to L in the exploded

F G H
diagrams indicate the types of lubricants and
lubrication points.
E G M F Apply engine oil
G Apply gear oil
I J K L H Apply molybdenum disulfide oil
I Apply wheel bearing grease
B LS M S J Apply lightweight lithium soap base grease
K Apply molybdenum disulfide grease
L Apply silicon grease
M N Illustrated symbols M to N in the exploded
diagrams indicate where to apply a locking

LT
New agent M and when to install a new part N.
M Apply the locking agent (LOCTITE®)
N Replace
 CONTENTS

GENERAL INFORMATION ................................................................................ 1

MACHINE IDENTIFICATION ....................................................................... 1
VEHICLE IDENTIFICATION NUMBER.................................................. 1

SPECIFICATIONS .............................................................................................. 2
GENERAL SPECIFICATIONS ..................................................................... 2
MAINTENANCE SPECIFICATIONS ............................................................ 3
ENGINE ................................................................................................. 3
CHASSIS ............................................................................................... 4
ELECTRICAL ......................................................................................... 5
CABLE ROUTING ........................................................................................ 6

PERIODIC CHECKS AND ADJUSTMENTS.................................................... 20

INTRODUCTION ........................................................................................ 20
PERIODIC MAINTENANCE/LUBRICATION.............................................. 20
SEAT, FENDERS AND FUEL TANK.......................................................... 22
HEADLIGHTS AND FRONT FENDER ................................................ 22
REAR FENDER ................................................................................... 24
LICENSE PLATE LIGHT AND REAR TURN SIGNAL LIGHTS ........... 26
CHASSIS.................................................................................................... 27
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................ 27
ADJUSTING THE DRIVE CHAIN SLACK............................................ 29
ELECTRICAL ............................................................................................. 31
ADJUSTING THE HEADLIGHT BEAM................................................ 31
REPLACING THE HEADLIGHT BULB ................................................ 31

CHASSIS .......................................................................................................... 34
REAR WHEELS AND REAR AXLE HUB ................................................... 34
INSTALLING THE SPEED SENSOR................................................... 36
REAR BRAKE ............................................................................................ 37
REAR BRAKE MASTER CYLINDER................................................... 37
INSTALLING THE REAR BRAKE MASTER CYLINDER..................... 39
BRAKE EQUALIZER .................................................................................. 40
BRAKE EQUALIZER............................................................................ 40
DISASSEMBLING THE BRAKE EQUALIZER ..................................... 42
CHECKING THE BRAKE EQUALIZER ............................................... 42
ASSEMBLING THE BRAKE EQUALIZER ........................................... 42
INSTALLING THE BRAKE EQUALIZER ............................................. 43
STEERING SYSTEM ................................................................................. 45
HANDLEBAR ....................................................................................... 45
INSTALLING THE LEFT REARVIEW MIRROR BRACKETS
AND CLUTCH LEVER ........................................................................ 47
INSTALLING THE METER ASSEMBLY .............................................. 47
STEERING STEM................................................................................ 48
INSTALLING THE STEERING LOCK STOPPER................................ 50
ELECTRICAL ................................................................................................... 51
ELECTRICAL COMPONENTS................................................................... 51
LIGHTING SYSTEM................................................................................... 53
CIRCUIT DIAGRAM............................................................................. 53
CHECKING THE LIGHTING SYSTEM ................................................ 54
SIGNALING SYSTEM ................................................................................ 57
CIRCUIT DIAGRAM............................................................................. 57
CHECKING THE SIGNALING SYSTEM.............................................. 59

YFM350R-W 2006 WIRING DIAGRAM

 GEN
MACHINE IDENTIFICATION INFO
EBS00009

GENERAL INFORMATION
MACHINE IDENTIFICATION
EBS00010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the right side of the frame.

–1–
 GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model YFM350R-W
Model code number N0A1
Basic weight
With oil and full fuel tank 184.0 kg (406 lb)
Tires
Type Tubeless
Size front AT21 × 7-10 24J
rear AT20 × 10-9 34J
Manufacturer front MAXXIS
rear MAXXIS
Type front C9207
rear M976
Brakes
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Dual disc brake (front) and single disc brake
(rear)
system Front and rear unified
operation Right foot operation
Headlight type HS1-Halogen
Bulb wattage × quantity
Headlight 12 V 35 W/35 W × 1
Auxiliary light 12 V 5 W × 1
Tail/brake light 12 V 5 W/21 W × 1
License plate light 12 V 5 W × 1
Front turn signal light 12 V 10 W × 2
Rear turn signal light 12 V 10 W × 2
Meter lighting EL (electro-luminescent lighting)
Neutral indicator light 12 V 1.7 W × 1
Reverse indicator light 12 V 1.7 W × 1
Turn signal indicator light LED
High beam indicator light LED

–2–
 MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE

Model YFM350R-W
Carburetor
I.D. mark 5YT1 00
Main jet (M.J) #142.5
Main air jet (M.A.J) #35
Jet needle (J.N) 5JFC39-3
Needle jet (N.J) P-0M
Pilot jet (P.J) #22.5
Pilot air jet (P.A.J.1) #65
(P.A.J.2) #165
Pilot outlet (P.O) 1
Bypass 1 (B.P.1) 0.8
Bypass 2 (B.P.2) 0.8
Bypass 3 (B.P.3) 0.8
Pilot screw turns out (P.S) 2-1/4
Valve seat (V.S) 2.5
Starter jet (G.S) #70
Throttle valve size (Th.V) #105
Fuel level (F.L) 4 ~ 5 mm (0.16 ~ 0.20 in)
Above the float chamber mating surface
Float height 13.0 mm (0.51 in)
Engine idling speed 1,450 ~ 1,550 r/min
Intake vacuum 33.3 kPa (250 mmHg, 9.86 inHg)

–3–
 MAINTENANCE SPECIFICATIONS SPEC
CHASSIS
Tightening torques

Tightening torque
Part to be tightened Thread size Remarks
Nm m · kg ft · lb
Front turn signal light bracket and frame M6 13 1.3 9.4
Headlight bracket and front turn signal light
M6 13 1.3 9.4
bracket
Front turn signal light and front turn signal light
M6 7 0.7 5.1
bracket
Headlight and headlight bracket M6 6 0.6 4.3
Horn and horn bracket M6 10 1.0 7.2
Horn bracket and frame M6 13 1.3 9.4
Rear turn signal light bracket and frame M6 10 1.0 7.2
Rear turn signal light and rear turn signal light
M6 7 0.7 5.1
bracket
Stabilizer bracket and handlebar M6 7 0.7 5.1 LT

Left rearview mirror bracket and handlebar M6 7 0.7 5.1

Steering lock assembly, front shock absorber and
M10 48 4.8 35
frame
Steering lock assembly bracket and steering lock
M8 28 2.8 20
assembly
Steering lock stopper and steering lock stopper
M8 28 2.8 20
bracket
Brake equalizer and steering lock assembly
M6 13 1.3 9.4
bracket
Brake hose (brake equalizer to brake hose joint)
M10 19 1.9 13
and brake hose joint
Brake equalizer union bolt M10 27 2.7 19
Brake equalizer plug M20 49 4.9 35
Rear brake master cylinder union bolt M10 27 2.7 19
Brake equalizer bleed screw M8 6 0.6 4.3
Speed sensor bracket and rear axle hub M12 120 12.0 85
Speed sensor magnet holder, drive sprocket
M10 55 5.5 40
bracket and drive sprocket
Speed sensor magnet locknut M6 13 1.3 9.4

–4–
 MAINTENANCE SPECIFICATIONS SPEC
ELECTRICAL

Model YFM350R-W
Horn
Horn type Plane
Model/manufacturer × quantity YF-12/NIKKO × 1
Maximum amperage 3.0 A
Performance 105 ~ 120 db/2 m (6.6 ft)
Coil resistance 1.15 ~ 1.25 Ω at 20 °C (68 °F)
Turn signal relay
Relay type Full-transistor
Model/manufacturer FE218BH/DENSO
Self-cancelling device built-in No
Turn signal blinking frequency 75 ~ 95 cycles/min.
Wattage 10 W × 2 + 3.4 W
Hazard light wattage 10 W × 4
Circuit breaker
Type Fuse
Amperage for individual circuit
Main fuse (including headlight and brake 15 A × 1
light)
Ancillary fuse (turn signal, horn, speedome- 7.5 A × 1
ter, auxiliary light, license plate light, taillight)

–5–
 CABLE ROUTING SPEC
CABLE ROUTING
1 Clutch cable È Fasten the clutch switch lead and handlebar
2 Parking brake cable switch lead with plastic bands.
3 Starter cable É Fasten the engine stop switch lead and front
4 Front brake hose brake light switch lead with plastic bands.
5 Front brake light switch lead Ê 53 ~ 54 mm (2.09 ~ 2.13 in)
6 Engine stop switch lead Ë 88 ~ 89 mm (3.46 ~ 3.50 in)
7 Throttle cable Ì Route the meter assembly lead along the han-
8 Clutch switch lead dlebar, and then pass it to the front of the lower
9 Handlebar switch lead section of the handlebar.
0 Meter assembly lead

12 3 È 4 É 5

Ê 9 8 7
Ë
6

–6–
 CABLE ROUTING SPEC
1 Throttle cable B Wire harness
2 Front brake hose C Front turn signal light lead (left)
3 Engine stop switch lead D Front turn signal light lead (right)
4 Front brake light switch lead E Rectifier/regulator lead
5 Meter assembly lead
6 Parking brake cable È Pass the clutch switch lead, handlebar switch
7 Clutch cable lead, neutral/reverse indicator light lead, front
8 Starter cable brake light switch lead, starter cable, and engine
9 Clutch switch lead stop switch lead through the guide.
0 Handlebar switch lead
A Neutral/reverse indicator light lead

3 4 5
6

8
2
9
1 0

È
A A
É Ë
0
A
B

Ê 3 9
E 4 8
A-A

D C

–7–
 CABLE ROUTING SPEC
É Make sure that the lead connections are posi-
tioned in the area shown in the illustration.
Ê Fasten the wire harness, front turn signal light
lead (right), horn lead, headlight lead, and front
turn signal light lead (left) with a plastic locking
tie.
Ë Fasten the handlebar switch lead, neutral/
reverse indicator light lead, clutch switch lead,
starter cable, front brake light switch lead, and
engine stop switch lead with a plastic locking tie.

3 4 5
6

8
2
9
1 0

È
A A
É Ë
0
A
B

Ê 3 9
E 4 8
A-A

D C

–8–
 CABLE ROUTING SPEC
1 Headlight lead A Clutch cable
2 Front turn signal light lead (left) B Parking brake cable
3 Brake hose (brake equalizer to brake hose joint) C Brake hose (brake hose joint to front brake cali-
4 Front brake hose per)
5 Ground lead D Brake hose joint
6 Ignition coil lead E Frame
7 Starter cable F Speed sensor lead
8 Wire harness G Sub-wire harness
9 Starter motor lead
0 Brake hose (rear brake master cylinder to brake
equalizer)

D
E
E
4
0
8
F F
G
9 Í
8
7
3 9 7 G
Ì C-C
B-B
A D
8 9
3
Î
0
7

D 6
4 5
È C
4 B
3
1 2
B

Ë Ê
A

C
B A 0 É

–9–
 CABLE ROUTING SPEC
È Pass the parking brake cable and clutch cable Í Fasten the speed sensor lead, sub-wire har-
through the cable guide. ness, wire harness, starter cable, and starter
É Pass the parking brake cable, clutch cable, and motor lead with a plastic locking tie.
brake hose (rear brake master cylinder to brake Î 90°
equalizer) through the cable guide.
Ê 25°
Ë Route the headlight lead so that it does not con-
tact the front panel.
Ì Fasten the wire harness, starter motor lead, and
starter cable with a plastic band. Face the end of
the plastic band down.

D
E
E
4
0
8
F F
G
9 Í
8
7
3 9 7 G
Ì C-C
B-B
A D
8 9
3
Î
0
7

D 6
4 5
È C
4 B
3
1 2
B

Ë Ê
A

C
B A 0 É

– 10 –
 CABLE ROUTING SPEC
1 Starter cable C Neutral switch lead
2 Fuel hose D Brake hose (rear brake master cylinder to brake
3 Carburetor air vent hose equalizer)
4 Crankcase breather hose E Parking brake cable
5 Speed sensor lead F Frame
6 Tail/brake light lead G Sub-wire harness
7 C.D.I. unit lead H Starter motor lead
8 Wire harness I Starting circuit cut-off relay
9 Reverse switch lead J C.D.I. unit
0 Negative battery lead K Starter relay
A Carburetor overflow hose L Positive battery lead
B A.C. magneto lead

F
1 F Ê F
Ê
H 5 H 5
8 5
G 8 G G
H 8
È C-C E-E
A-A
H
É
F F
8 Ë F
G
5 8 5
Ì
G H G
B-B D-D F-F
1
1
2
3
4

D 5
A B
G
C F
A E
C
E 6
B
D
F

7
G
G Í

Î
L H
8
K 0
9
J
I
E D C B A 0
G-G

– 11 –
 CABLE ROUTING SPEC
È Pass a plastic band through the hole in the fuel Ë Fasten the wire harness and starter motor lead
tank shield, and then fasten the wire harness, with a plastic band. Face the end of the plastic
starter motor lead, starter cable, speed sensor band inward.
lead, and sub-wire harness with the plastic Ì Fasten the sub-wire harness with a plastic lock-
band. The end of the plastic band should be ing tie.
under the frame, facing inward. Í Connect the sub-wire harness to the wire har-
É Route the wire harness, starter motor lead, ness.
speed sensor lead, and sub-wire harness above Î Connect the tail/brake light lead to the wire har-
the starter cable. ness.
Ê Fasten the wire harness, starter motor lead,
speed sensor lead, and sub-wire harness with a
plastic locking tie.

F
1 F Ê F
Ê
H 5 H 5
8 5
G 8 G G
H 8
È C-C E-E
A-A
H
É
F F
8 Ë F
G
5 8 5
Ì
G H G
B-B D-D F-F
1
1
2
3
4

D 5
A B
G
C F
A E
C
E 6
B
D
F

7
G
G Í

Î
L H
8
K 0
9
J
I
E D C B A 0
G-G

– 12 –
 CABLE ROUTING SPEC
1 Brake hose (rear brake master cylinder to brake A Brake hose (brake hose joint to front brake cali-
equalizer) per)
2 Parking brake cable B Spark plug lead
3 Drive select lever switch lead C Starter motor lead
4 Ground terminal D Headlight lead (not used)
5 Throttle cable
6 Main switch lead È Fasten the headlight lead (not used) with a plas-
7 Front brake hose tic locking tie. Also, fasten the wire harness with
8 Brake hose (brake equalizer to brake hose joint) a plastic locking tie in the same way on the left
9 Front turn signal light lead (right) side of the vehicle.
0 Horn lead

È D

A-A

7
1 2 3 4 3 5 6

A
8
A
9

C B A 0

– 13 –
 CABLE ROUTING SPEC
1 Rear brake hose È Fasten the rear brake light switch lead and
2 Parking brake cable speed sensor lead with the plastic band.
3 Brake fluid reservoir hose
4 Rear brake light switch lead
5 Brake hose (rear brake master cylinder to brake
equalizer)
6 Speed sensor lead
7 Frame

1 7

5 6
È
4
A C-C

4 7

6 4

C C È
D-D

3 B
D D A

6 B

1 2

– 14 –
 CABLE ROUTING SPEC
1 Front turn signal light lead (left) B Throttle cable
2 Horn lead C Ignition coil lead
3 Headlight lead D Ground lead
4 Front turn signal light lead (right) E Frame
5 Rectifier/regulator lead
6 Main switch lead
7 Spark plug lead
8 Drive select lever switch lead
9 Starter motor lead
0 Wire harness
A Sub-wire harness

3 2
2
1 4

A A
É
A-A
B B
5
Ê Ë
2
4 3 1
C C

D
E E
C B-B

È
7
E

4
B
1
A 3 0
Ì 2
0 8 C-C

– 15 –
 CABLE ROUTING SPEC
È Make sure that the lead connections are posi- Ì Fasten the front turn signal light lead (left), head-
tioned in the area shown in the illustration. light lead, front turn signal light lead (right), horn
É Fasten the headlight lead with a plastic locking lead, and wire harness with a plastic locking tie.
tie.
Ê Fasten the front turn signal light lead (right) with
a plastic locking tie.
Ë Fasten the horn lead, headlight lead, and front
turn signal light lead (left) with a plastic locking
tie.

3 2
2
1 4

A A
É
A-A
B B
5
Ê Ë
2
4 3 1
C C

D
E E
C B-B

È
7
E

4
B
1
A 3 0
Ì 2
0 8 C-C

– 16 –
 CABLE ROUTING SPEC
1 Starter relay A Negative battery lead
2 Positive battery lead B Starting circuit cut-off relay
3 C.D.I. unit C Starter motor lead
4 Battery D Sub-wire harness
5 Ancillary fuse (turn signal, horn, speedometer, E Wire harness
auxiliary light, license plate light, taillight)
6 Turn signal relay È Make sure that the lead connections are posi-
7 Rear turn signal light lead (right) tioned in the area shown in the illustration.
8 License plate light lead É Fasten the tail/brake light lead with a plastic
9 Rear turn signal light lead (left) locking tie.
0 Tail/brake light lead

D
1

2
C
3

B 4

A 6

7
9
8

– 17 –
 CABLE ROUTING SPEC
1 Rear turn signal light lead (left) È 35 ~ 45 mm (1.38 ~ 1.77 in)
2 License plate light lead É 15 ~ 25 mm (0.59 ~ 0.98 in)
3 Rear turn signal light lead (right) Ê Fasten the license plate light lead with a plastic
clamp.
Ë Fasten the rear turn signal light lead with a plas-
tic clamp.
Ì 15 mm (0.59 in)
Í Fasten the rear turn signal light lead with the
plastic locking tie.

1 3
È 2 È
A A

A
A

2 Ê

B
É

13
13 Í
Ì

B-B
A-A

– 18 –
 CABLE ROUTING SPEC
1 Rear brake hose È Fasten the parking brake cable and speed sen-
2 Parking brake cable sor lead with a plastic locking tie.
3 Speed sensor lead É Fasten the speed sensor lead at the white mark
on the lead with a plastic locking tie.

1 2 È

A
É

2 2
3
A-A È

– 19 –
 INTRODUCTION/ CHK
PERIODIC MAINTENANCE/LUBRICATION ADJ
EB300000

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. 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 inter-
vals.
• 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.

INITIAL EVERY

Whichever month 1 3 6 6 12
ITEM ROUTINE comes first km 320 1,200 2,400 2,400 4,800
(mi) (200) (750) (1,500) (1,500) (3,000)
hours 20 75 150 150 300
• Check valve clearance.
Valves*
• Adjust if necessary.
• Check condition.
Spark plug • Adjust gap and clean.
• Replace if necessary.
• Clean. Every 20 ~ 40 hours
Air filter element
• Replace if necessary. (More often in wet or dusty areas.)
• Check starter (choke) operation.
Carburetor*
• Adjust engine idling speed.
Crankcase breather • Check breather hose for cracks or damage.
system* • Replace if necessary.
• Check for leakage.
Exhaust system* • Tighten if necessary.
• Replace gasket(s) if necessary.
• Check fuel hose for cracks or damage.
Fuel line*
• Replace if necessary.
Engine oil • Replace. (Warm engine before draining.)
Engine oil filter ele- • Clean.
ment • Replace if necessary.
Engine oil strainer • Clean.
Drive chain • Check and adjust slack/alignment/clean/lube.
• Check operation/fluid leakage/See NOTE page 21.
Brakes*
• Correct if necessary.
• Check operation.
Clutch*
• Adjust if necessary.
• Check balance/damage/runout.
Wheels*
• Replace if necessary.
• Check bearing assemblies for looseness/damage.
Wheel bearings*
• Replace if damaged.

– 20 –
 CHK
PERIODIC MAINTENANCE/LUBRICATION ADJ
INITIAL EVERY

Whichever month 1 3 6 6 12
ITEM ROUTINE comes first km 320 1,200 2,400 2,400 4,800
(mi) (200) (750) (1,500) (1,500) (3,000)
hours 20 75 150 150 300
• Check operation.
• Repair if damaged.
Steering system*
• Check toe-in.
• Adjust if necessary.
Front and rear • Check operation.
suspension* • Correct if necessary.
Upper and lower arm
• Lubricate every 6 months with lithium-soap-based
pivot and steering
grease.
shaft*
• Lubricate every 6 months with lithium-soap-based
Rear arm pivot*
grease.
Fittings and fasten- • Check all chassis fittings and fasteners.
ers* • Correct if necessary.
• Check operation.
Lights and switches*
• Adjust headlight beams.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser-
vice.
NOTE:
_

• Recommended brake fluid: DOT 4

• Brake fluid replacement:
• When disassembling the master cylinders or calipers, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
• On the inner parts of the master cylinders and calipers, replace the oil seals every two years.
• On the inner parts of the brake equalizer, replace the piston seals and O-ring every two years.
• Replace the brake hoses every four years, or if cracked or damaged.

– 21 –
 CHK
SEAT, FENDERS AND FUEL TANK ADJ
EBS00036

SEAT, FENDERS AND FUEL TANK

HEADLIGHTS AND FRONT FENDER

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.

13
R.

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
12 7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
11

3 1
9

2
4

7 6
5 10
13 Nm (1.3 m • kg, 9.4 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.

T
R.

.
R.

13 Nm (1.3 m • kg, 9.4 ft • Ib) 13 Nm (1.3 m • kg, 9.4 ft • Ib)

6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
T.

T.
R.

R.

Order Job/Part Q’ty Remarks

Removing the headlights and front Remove the parts in the order listed.
fender
Seat/side covers (left and right)/front Refer to “SEAT, SIDE COVERS, AND
panel FRONT PANEL”.
(Manual No.: 3GD-AE7)
1 Headlight coupler 1 Disconnect.
2 Auxiliary light connector 1 Disconnect.
3 Headlight assembly 1
4 Front turn signal light coupler (left) 1 Disconnect.
5 Front turn signal light (left) 1
6 Front turn signal light coupler (right) 1 Disconnect.
7 Front turn signal light (right) 1
8 Horn connector 2 Disconnect.
9 Horn 1

– 22 –
 CHK
SEAT, FENDERS AND FUEL TANK ADJ

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.

13
R.

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
12 7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
11

3 1
9

2
4

7 6
5 10
13 Nm (1.3 m • kg, 9.4 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.

T
R.

.
R.

13 Nm (1.3 m • kg, 9.4 ft • Ib) 13 Nm (1.3 m • kg, 9.4 ft • Ib)

6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
T.

T.
R.

R.

Order Job/Part Q’ty Remarks

10 Left headlight 1 Do not connect to the wire harness. This
headlight is not used.
11 Right headlight 1 Do not connect to the wire harness. This
headlight is not used.
12 Main switch coupler 1 Disconnect.
13 Front fender 1
For installation, reverse the removal pro-
cedure.

– 23 –
 CHK
SEAT, FENDERS AND FUEL TANK ADJ
EBS00039

REAR FENDER

3 Nm (0.3 m • kg, 2.2 ft • Ib)

T.
R.

3 Nm (0.3 m • kg, 2.2 ft • Ib)

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
1
2
6
9 3

10
7 11
8
5
4 12

16
14

12 13
15
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

Order Job/Part Q’ty Remarks

Removing the rear fender Remove the parts in the order listed.
Seat/side covers (left and right) Refer to “SEAT, SIDE COVERS, AND
FRONT PANEL”.
(Manual No.: 3GD-AE7)
1 Battery holding bracket 1
2 Battery lead 2 CAUTION:
_

First disconnect the negative lead,

then disconnect the positive lead.

3 Battery 1
4 Crankcase breather hose 1 Disconnect.
5 Clamp screw 1 Loosen.
6 Air filter case 1
7 Starter relay 1
8 Starting circuit cut-off relay 1

– 24 –
 CHK
SEAT, FENDERS AND FUEL TANK ADJ

3 Nm (0.3 m • kg, 2.2 ft • Ib)

T.
R.

3 Nm (0.3 m • kg, 2.2 ft • Ib)

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
1
2
6
9 3

10
7 11
8
5
4 12

16
14

12 13
15
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

Order Job/Part Q’ty Remarks

9 C.D.I. unit 1
10 Turn signal relay 1
11 Ancillary fuse (turn signal, horn, speed- 1
ometer, auxiliary light, license plate
light, taillight)
12 Tail/brake light coupler 2 Disconnect.
13 Rear turn signal light coupler 2 Disconnect.
14 License plate light coupler 1 Disconnect.
15 Carburetor air vent hose 1 Disconnect.
16 Rear fender 1
For installation, reverse the removal pro-
cedure.

– 25 –
 CHK
SEAT, FENDERS AND FUEL TANK ADJ

LICENSE PLATE LIGHT AND REAR TURN SIGNAL LIGHTS

7 Nm (0.7 m • kg, 5.1 ft • Ib)

4
T.
R.

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
3

7
1
2

5
6

Order Job/Part Q’ty Remarks

Removing the license plate light and Remove the parts in the order listed.
rear turn signal lights
1 License plate light coupler 1 Disconnect.
2 License plate light 1
3 Rear turn signal light coupler (left) 1 Disconnect.
4 Rear turn signal light (left) 1
5 Rear turn signal light coupler (right) 1 Disconnect.
6 Rear turn signal light (right) 1
7 Rear reflector 2
For installation, reverse the removal pro-
cedure.

– 26 –
 CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
CHASSIS
EBS00094
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
_

Bleed the hydraulic brake system when-

ever:
• the system is disassembled,
• a brake hose is loosened, disconnected
or replaced,
• the brake fluid level is very low,
• brake operation is faulty.

NOTE:
_

• Be careful not to spill any brake fluid or allow

the brake master cylinder reservoir or brake
fluid reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably length-
ening the bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.

1. Bleed:
• hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder
reservoir or brake fluid reservoir).

– 27 –
 CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
È c. Connect a clear plastic hose 1 tightly to the
1 bleed screw 2.
È Front brake caliper
É Brake equalizer
Ê Rear brake caliper
2 NOTE:
The bleeding order of the hydraulic brake sys-
tem is the following:
1. Front brake calipers
2. Brake equalizer
3. Rear brake caliper
É

1 d. Place the other end of the hose into a con-

tainer.
e. Slowly apply the brake lever or brake pedal
several times.
2 f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in posi-
tion.
g. Loosen the bleed screw.

Ê NOTE:
_

Loosening the bleed screw will release the

pressure and cause the brake lever to contact
the throttle grip or the brake pedal to fully
1 extend.

h. Tighten the bleed screw and then release

2 the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
NOTE:
If the air is not completely bled from the
hydraulic system after bleeding the rear brake
caliper, repeat the bleeding procedure for the
brake equalizer and the rear brake caliper.

j. Tighten the bleed screw to specification.

Bleed screw
6 Nm (0.6 m · kg, 4.3 ft · lb)
T.
R.

– 28 –
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” in chapter 3. (Manual No.: 3GD-AE5)
WARNING
_

After bleeding the hydraulic brake system,

check the brake operation.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ADJUSTING THE DRIVE CHAIN SLACK

NOTE:
The drive chain slack must be checked at the
tightest point on the chain.

CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.

1. Elevate the rear wheels by placing the suit-

able stand under the frame.

2. Measure:
• drive chain slack a
Out of specification → Adjust.

Drive chain slack

25 ~ 35 mm (0.98 ~ 1.38 in)

3. Adjust:
• drive chain slack
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the rear axle hub upper nut 1.
b. Loosen the rear axle hub lower nut 2.

– 29 –
 CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
c. Loosen the locknuts 3.
d. Turn both adjusting bolts 4 in direction a
or b until the specified drive chain slack is
obtained.

Drive chain slack is

Direction a
reduced.
Drive chain slack is
Direction b
increased.

NOTE:
To maintain the proper axle alignment, adjust
both sides evenly. (There are marks c on
each side of the swingarm and on the drive
chain pullers.)

CAUTION:
Excessive chain slack will overload the
engine and other vital parts; keep the slack
within the specified limits.

e. If the chain slack cannot be adjusted,

replace the sprockets and drive chain as a
set.
f. Tighten the axle hub bolts and locknuts.

Rear axle hub upper bolt

120 Nm (12.0 m · kg, 85 ft · lb)
T.
R.

Rear axle hub lower bolt

73 Nm (7.3 m · kg, 53 ft · lb)
Locknut (chain puller)
16 Nm (1.6 m · kg, 11 ft · lb)
5
NOTE:
d • Make sure that the curved edge d of the
speed sensor bracket 5 is contacting the
rear axle hub 6 when tightening the hub
bolts.
• The chain should be cleaned and lubricated
6
after every use of the machine.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

– 30 –
 ADJUSTING THE HEADLIGHT BEAM/ CHK
REPLACING THE HEADLIGHT BULB ADJ
ELECTRICAL
5 cm ADJUSTING THE HEADLIGHT BEAM
(1.97 in) 1. Check:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
H a. Set the tire pressures and adjust the shock
absorbers to the specifications.
5 m (16 ft) b. Place the vehicle on a level surface, 5 m
H
(16 ft) from a wall.
c. Measure the distance “H” from the floor to
the center of the headlight, and then place a
mark on the wall at that height.
d. Place another mark on the wall, 5 cm
(1.97 in) lower than the mark made in step
(c).
e. Apply the parking brake, start the engine,
and let it idle.
f. Switch on the low beam, and then check the
height of the headlight beam on the wall
while straddling the vehicle. The headlight
beam cut off line (the border between dark
and bright) should be aligned with the mark
made in step (d). Adjust the headlight beam
if it is not aligned with the mark.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Adjust:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the screws 1.
1 1 b. Position the headlight body up or down to
adjust the headlight beam.
c. Tighten the screws 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EBS00124
REPLACING THE HEADLIGHT BULB
1. Remove:
• headlight assembly 1
1

– 31 –
 CHK
REPLACING THE HEADLIGHT BULB ADJ
2. Remove:
• headlight body 1

3. Disconnect:
• headlight coupler 1
1 4. Remove:
• auxiliary light bulb socket 2
2

5. Remove:
1 • headlight bulb cover 1

6. Detach:
2 • headlight bulb holder 1
1
7. Remove:
• headlight bulb 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.

– 32 –
 CHK
REPLACING THE HEADLIGHT BULB ADJ
8. Install:
• headlight bulb New
CAUTION:
_

Avoid touching the glass part of the bulb.

Keep it free from oil; otherwise, the trans-
parency 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 lac-
quer thinner.

9. Attach:
• headlight bulb holder
10.Install:
• headlight bulb cover
11.Install:
• auxiliary light bulb socket
12.Connect:
• headlight coupler
13.Install:
• headlight body 1
• headlight assembly
a NOTE:
Fit the headlight lead grommet 2 securely into
1 the hole a in the headlight body.

– 33 –
 REAR WHEELS AND REAR AXLE HUB CHAS
CHASSIS
REAR WHEELS AND REAR AXLE HUB

(4) 3
1 New 120 Nm (12.0 m • kg, 85 ft • lb)

.
R.
28 Nm (2.8 m • kg, 20 ft • Ib) 2 7 Nm (0.7 m • kg, 5.1 ft • Ib)
.
R.

.
R.
4
LT
5
160 Nm (16.0 m • kg, 115 ft • lb)
6

.
R.
LT
LT
5 11 (4) 17 15

10 LS
(4) LT 16 (4)

9 34 Nm (3.4 m • kg, 24 ft • Ib)

.
R.
19 120 Nm (12.0 m • kg, 85 ft • lb)
8

.
R.
7
LS

16 Nm (1.6 m • kg, 11 ft • Ib) 18 12

.
R.

8
7
4 14
19
2 3

13
New 1 (4)
55 Nm (5.5 m • kg, 40 ft • Ib)
.
R.

73 Nm (7.3 m kg, 53 ft • lb)

•
120 Nm (12.0 m • kg, 85 ft • lb)
.
R.
.
R.

45 Nm (4.5 m • kg, 32 ft • Ib) 13 Nm (1.3 m • kg, 9.4 ft • Ib)

T.
.
R.

R.

Order Job/Part Q’ty Remarks

Removing the rear wheels and rear Remove the parts in the order listed.
axle hub
1 Cotter pin 2 Refer to “REAR WHEEL AND WHEEL
2 Axle nut 2 HUB” in chapter 6.
3 Rear wheel 2 (Manual No.: 3GD-AE5)
4 Wheel hub 2
5 Bolt 2
Refer to “REMOVING THE REAR
6 Nut 1
AXLE” and “INSTALLING THE REAR
7 Locknut 2
AXLE”. (Manual No.: 3GD-AE7)
8 Adjusting bolt 2
9 Brake caliper 1 NOTE:
Do not apply the brake pedal and do not
use the parking brake when the brake
caliper is off of the brake disc as the
brake pad will be force shut.

– 34 –
 REAR WHEELS AND REAR AXLE HUB CHAS

(4) 3
1 New 120 Nm (12.0 m • kg, 85 ft • lb)

.
R.
28 Nm (2.8 m • kg, 20 ft • Ib) 2 7 Nm (0.7 m • kg, 5.1 ft • Ib)
.
R.

.
R.
4
LT
5
160 Nm (16.0 m • kg, 115 ft • lb)
6

.
R.
LT
LT
5 11 (4) 17 15

10 LS
(4) LT 16 (4)

9 34 Nm (3.4 m • kg, 24 ft • Ib)

.
R.
19 120 Nm (12.0 m • kg, 85 ft • lb)
8

.
R.
7
LS

16 Nm (1.6 m • kg, 11 ft • Ib) 18 12

.
R.

8
7
4 14
19
2 3

13
New 1 (4)
55 Nm (5.5 m • kg, 40 ft • Ib)
.
R.

73 Nm (7.3 m • kg, 53 ft • lb)

120 Nm (12.0 m • kg, 85 ft • lb)
.
R.
.
R.

45 Nm (4.5 m • kg, 32 ft • Ib) 13 Nm (1.3 m • kg, 9.4 ft • Ib)

T.
.
R.

R.

Order Job/Part Q’ty Remarks

10 Brake disc/brake disc bracket 1/1
11 Rear axle 1 Refer to “REMOVING THE REAR AXLE”.
(Manual No.: 3GD-AE7)
12 Speed sensor magnet 1
13 Speed sensor magnet holder 1
14 Driven sprocket/sprocket bracket 1/1 Refer to “INSTALLING
15 Speed sensor coupler 1 Disconnect. THE SPEED SENSOR”.
16 Speed sensor 1
17 Speed sensor bracket 1
18 Rear axle hub 1
19 Spacer/bearing/oil seal 1/2/2
For installation, reverse the removal pro-
cedure.

– 35 –
 REAR WHEELS AND REAR AXLE HUB CHAS
INSTALLING THE SPEED SENSOR
1. Install:
1
• speed sensor bracket 1
a 120 Nm (12.0 m · kg, 85 ft · lb)

T.
R.
NOTE:
Make sure that the curved edge a of the
speed sensor bracket 1 contacts the rear axle
hub 2.
2

2. Install:
3 • speed sensor magnet 1
a 13 Nm (1.3 m · kg, 9.4 ft · lb)

T.
R.
• speed sensor magnet holder 2
NOTE:
Install the speed sensor magnet as shown.

2 1 b 3 Speed sensor
a 19.0 ~ 21.0 mm (0.75 ~ 0.83 in)
b 1.5 ~ 1.7 mm (0.059 ~ 0.067 in)

– 36 –
 REAR BRAKE CHAS
EBS00410

REAR BRAKE
REAR BRAKE MASTER CYLINDER

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

2
3
4
5
1

10

7
8 New
6
9
8 New

11
New 27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.

23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.

Order Job/Part Q’ty Remarks

Removing the rear brake master cyl- Remove the parts in the order listed.
inder
Right foot protector Refer to “FOOT PROTECTORS,
ENGINE SKID PLATE, AND FRONT
BUMPER”. (Manual No.: 3GD-AE7)
Brake fluid Drain.
1 Brake fluid reservoir cover 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1

– 37 –
 REAR BRAKE CHAS

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

2
3
4
5
1

10

7
8 New
6
9
8 New

11
New 27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.

23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.

Order Job/Part Q’ty Remarks

7 Union bolt 1
8 Copper washer 3
Refer to “INSTALLING
9 Brake hose (rear brake master cylinder 1 Disconnect.
THE REAR BRAKE MAS-
to brake equalizer)
TER CYLINDER”.
10 Rear brake hose 1 Disconnect.
11 Rear brake master cylinder 1
For installation, reverse the removal pro-
cedure.

– 38 –
 REAR BRAKE CHAS
EBS00419

a INSTALLING THE REAR BRAKE MASTER

180˚ CYLINDER
1. Install:
2 • copper washers New
• rear brake hose 1
1 • brake hose (rear brake master cylinder to
b brake equalizer) 2
3
• union bolt 3 27 Nm (2.7 m · kg, 19 ft · lb)

T.
R.
CAUTION:
_

• When installing the rear brake hose onto

the brake master cylinder, make sure the
brake pipe a touches the projection b as
shown.
• Install the brake hose (rear brake master
cylinder to brake equalizer) at a 180°
angle from the rear brake hose.

WARNING
_

Proper brake hose routing is essential to

insure safe machine operation. Refer to
“CABLE ROUTING”.

– 39 –
 BRAKE EQUALIZER CHAS
BRAKE EQUALIZER
BRAKE EQUALIZER

27 Nm (2.7 m • kg, 19 ft • Ib) 27 Nm (2.7 m • kg, 19 ft • Ib)

1
T.
R.

T.
R.
3
1
2 New
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.

New 2

1 5
4

New 2

19 Nm (1.9 m • kg, 13 ft • Ib)

T.
R.

13 Nm (1.3 m • kg, 9.4 ft • Ib)

T.
R.

Order Job/Part Q’ty Remarks

Removing the brake equalizer Remove the parts in the order listed.
Brake fluid Drain.
1 Union bolt 3
2 Copper washer 6
Refer to “INSTALLING
3 Front brake hose 1 Disconnect.
THE BRAKE EQUAL-
4 Brake hose (brake equalizer to brake 1
IZER”.
hose joint)
5 Brake hose (rear brake master cylinder 1 Disconnect.
to brake equalizer)
6 Brake equalizer 1
For installation, reverse the removal pro-
cedure.

– 40 –
 BRAKE EQUALIZER CHAS
EBS00411

6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.
R.

4
3 2 New
1

7 5

49 Nm (4.9 m • kg, 35 ft • Ib)

T.
R.

Order Job/Part Q’ty Remarks

Disassembling the brake equalizer Remove the parts in the order listed.
1 Brake equalizer plug 1
2 O-ring 1
3 Spring 1 Refer to “DISASSEMBLING THE
4 Piston seal 3 BRAKE EQUALIZER” and “ASSEM-
5 Piston 1 BLING THE BRAKE EQUALIZER”.
6 Bleed screw 1
7 Brake equalizer 1
For assembly, reverse the disassembly
procedure.

– 41 –
 BRAKE EQUALIZER CHAS
DISASSEMBLING THE BRAKE EQUALIZER
1. Remove:
• brake equalizer piston seals
1 • brake equalizer piston 1
2
NOTE:
Drive the piston out of the brake equalizer by
inserting a rod 2 into the brake hose installa-
tion hole shown.

EBS00413
CHECKING THE BRAKE EQUALIZER
1. Check:
• brake equalizer 1
Wear/scratches → Replace the brake
equalizer.
• brake equalizer body
1 Cracks/damage → Replace.
• brake fluid delivery passage
(brake equalizer body)
Blockage → Blow out with compressed air.
2. Check:
1 • piston 1
3 • piston seals 2
4 • spring 3
• O-ring 4
2 Scratches/wear/damage → Replace.

EBS00416
ASSEMBLING THE BRAKE EQUALIZER
WARNING
_

• All internal brake components should be

cleaned and lubricated with new brake
fluid only before installation.

Recommended brake fluid

DOT 4

• Whenever a brake equalizer is disassem-

bled, replace the piston seals and O-ring.

– 42 –
 BRAKE EQUALIZER CHAS
EBS00419

1 INSTALLING THE BRAKE EQUALIZER

1. Install:
• copper washers New
6 • brake hose (rear brake master cylinder to
25˚ brake equalizer) 1
• brake hose (brake equalizer to brake hose
4
joint) 2
5
• front brake hose 3
• union bolts 4
27 Nm (2.7 m · kg, 19 ft · lb)

T.
R.
CAUTION:
3 2
4
_

90˚ Install the brake hoses onto the brake

equalizer at the angles shown in the illus-
trations.

4 4 WARNING
_

3 Proper brake hose routing is essential to

6 4
insure safe machine operation. Refer to
“CABLE ROUTING”.

4
5 Brake equalizer
6 Steering stem
5 2. Fill:
• brake fluid reservoir

Recommended brake fluid

2
DOT 4

CAUTION:
_

Brake fluid may damage painted surfaces

or plastic parts. Always clean up spilled
brake fluid immediately.

WARNING
_

• Use only the designated quality brake

fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harm-
ful chemical reaction and lead to poor
brake performance.
• Be careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.

– 43 –
 BRAKE EQUALIZER CHAS
3. Air bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM”.
4. Check:
• brake fluid level
Brake fluid level is under the “LOWER” level
line → Add the recommended brake fluid to
the proper level.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” in chapter 3.
(Manual No.: 3GD-AE5)

– 44 –
 STEERING SYSTEM CHAS
EBS00444

STEERING SYSTEM
HANDLEBAR

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
7 4
8
9
19
3
13 6
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
11
13 5
12 LT
1 5 17
12 2
5
5 22
4 7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
16

R.
20 Nm (2.0 m • kg, 14 ft • Ib) 20
17
T.
R.

23 21
10 5

14 16
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

15

19
18

Order Job/Part Q’ty Remarks

Removing the handlebar Remove the parts in the order listed.
1 Stabilizer pad cover 1
2 Stabilizer pad 1
3 Meter assembly coupler 2 Disconnect.
4 Meter assembly/bracket 1/1 Refer to “INSTALLING THE METER
ASSEMBLY”.
5 Stabilizer/bracket 1/4
6 Neutral/reverse indicator light coupler 1 Disconnect.
7 Handlebar cover 1
8 Left rearview mirror 1
9 Right rearview mirror 1
10 Front brake light switch 1
11 Brake master cylinder/bracket 1/1
12 Engine stop switch/bracket 1/1

– 45 –
 STEERING SYSTEM CHAS

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
7 4
8
9
19
3
13 6
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
11
13 5
12 LT
1 5 17
12 2
5
5 22
4 7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
16

R.
20 Nm (2.0 m • kg, 14 ft • Ib) 20
17
T.
R.

23 21
10 5

14 16
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

15

19
18

Order Job/Part Q’ty Remarks

13 Throttle lever assembly/bracket 1/1
14 Clutch switch 1
15 Parking brake lever 1
16 Clutch lever/bracket 1/1 Refer to “INSTALLING THE LEFT
17 Left rearview mirror bracket 2 REARVIEW MIRROR BRACKETS AND
CLUTCH LEVER”.
18 Handlebar switch 1
19 Handlebar grip 2
20 Starter cable 1 Disconnect.
21 Starter lever 1
22 Handlebar holder 2 Refer to “STEERING SYSTEM” in chap-
23 Handlebar 1 ter 6. (Manual No.: 3GD-AE5)
For installation, reverse the removal pro-
cedure.

– 46 –
 STEERING SYSTEM CHAS
INSTALLING THE LEFT REARVIEW
21 3 MIRROR BRACKETS AND CLUTCH LEVER
1. Install:
• clutch lever
• clutch lever bracket 1
• parking brake lever 2
7 Nm (0.7 m · kg, 5.1 ft · lb)

T.
R.
a • left rearview mirror bracket 3
b 7 Nm (0.7 m · kg, 5.1 ft · lb)

T.
R.
NOTE:
Install the clutch lever bracket and left rearview
mirror brackets as shown.

a 53 ~ 54 mm (2.09 ~ 2.13 in)

b 88 ~ 89 mm (3.46 ~ 3.50 in)

INSTALLING THE METER ASSEMBLY

1. Install:
1 • meter assembly 1
a • meter assembly bracket
NOTE:
Be sure to fit the projection a on the meter
2 assembly into the hole b in the stabilizer 2.
b

– 47 –
 STEERING SYSTEM CHAS
EBS00454

STEERING STEM

48 Nm (4.8 m • kg, 35 ft • Ib) 28 Nm (2.8 m • kg, 20 ft • Ib)

T.
T.

R.
R.
21
LS
10
8 New 11 10

9 12 LS

LS LS

23 Nm (2.3 m • kg, 17 ft • Ib) 4 3 3 2

T.
R.

28 Nm (2.8 m • kg, 20 ft • Ib) 5

T.
R.

1 7
New
New

6 New
15
14
LS
13 25 Nm (2.5 m • kg, 18 ft • Ib)
T.
R
15 Nm (1.5 m • kg, 11 ft • Ib)
T . R.

13 New 18 25 Nm (2.5 m • kg, 18 ft • Ib)

T.
R.

25 Nm (2.5 m • kg, 18 ft • Ib)

19
.T
R
.

40 Nm (4.0 m • kg, 29 ft • Ib) LS 14 New

20
T.
R.

17 New
35 Nm (3.5 m • kg, 25 ft • Ib) 16
T.
R.

15
15 Nm (1.5 m • kg, 11 ft • Ib)
T.
R.

Order Job/Part Q’ty Remarks

Removing the steering stem Remove the parts in the order listed.
Side covers (left and right)/fuel tank Refer to “SEAT, FENDERS AND FUEL
shield TANK”. (Manual No.: 3GD-AE7)
Front fender Refer to “SEAT, FENDERS AND FUEL
TANK”.
Brake equalizer Refer to “BRAKE EQUALIZER”.
1 Steering lock assembly 1
2 Steering lock assembly bracket 1
3 Steering stem bushing 2
4 Spacer 2
5 Oil seal 2
6 Steering lock stopper 1 Refer to “INSTALLING THE STEERING
7 Steering lock stopper bracket 1 LOCK STOPPER”.
8 Lock washer 1
9 Cable guide 1

– 48 –
 STEERING SYSTEM CHAS

48 Nm (4.8 m • kg, 35 ft • Ib) 28 Nm (2.8 m • kg, 20 ft • Ib)

T.
T.

R.
R.
21
LS
10
8 New 11 10

9 12 LS

LS LS

23 Nm (2.3 m • kg, 17 ft • Ib) 4 3 3 2

T.
R.

28 Nm (2.8 m • kg, 20 ft • Ib) 5

T.
R.

1 7
New
New

6 New
15
14
LS
13 25 Nm (2.5 m • kg, 18 ft • Ib)
T.
R
15 Nm (1.5 m • kg, 11 ft • Ib)
T . R.

13 New 18 25 Nm (2.5 m • kg, 18 ft • Ib)

T.
R.

25 Nm (2.5 m • kg, 18 ft • Ib)

19
.T
R
.

40 Nm (4.0 m • kg, 29 ft • Ib) LS 14 New

20
T.
R.

17 New
35 Nm (3.5 m • kg, 25 ft • Ib) 16
T.
R.

15
15 Nm (1.5 m • kg, 11 ft • Ib)
T.
R.

Order Job/Part Q’ty Remarks

10 Steering stem bushing 2
11 Spacer 2
12 Oil seal 2
13 Right-hand-thread ball joint 2
Refer to “STEERING SYSTEM” in chap-
14 Tie-rod 2
ter 6. (Manual No.: 3GD-AE5)
15 Left-hand-thread ball joint 2
16 Spacer 1
17 Oil seal 1
18 Oil seal 1
19 Bearing retainer 1
20 Bearing 1
21 Steering stem 1
For installation, reverse the removal pro-
cedure.

– 49 –
 STEERING SYSTEM CHAS
INSTALLING THE STEERING LOCK
2 1 STOPPER
1. Install:
• steering lock stopper bracket 1
• steering lock stopper 2
28 Nm (2.8 m · kg, 20 ft · lb)

T.
R.
3 NOTE:
a Make sure that the projection a on the steer-
ing lock stopper bracket contacts the pitman
arm 3.

– 50 –
 – +
ELECTRICAL COMPONENTS ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1 Rectifier/regulator 9 Drive select lever switch
2 Main switch 0 Rear turn signal light
3 Neutral indicator light A License plate light
4 Reverse indicator light B Turn signal relay
5 Meter assembly C Ancillary fuse (turn signal, horn, speedometer,
6 Engine stop switch auxiliary light, license plate light, taillight)
7 Ignition coil D Battery
8 Handlebar switch E C.D.I. unit

3
7

4 6
8
9
2 A
0

P B
C

1
D
O
E
M

N L
G
N J

K H F
I

– 51 –
 – +
ELECTRICAL COMPONENTS ELEC
F Starting circuit cut-off relay
G Main fuse
H Starter relay
I Speed sensor
J Reverse switch
K Neutral switch
L Rear brake light switch
M Horn
N Front turn signal light
O Headlight
P Wire harness

3
7

4 6
8
9
2 A
0

P B
C

1
D
O
E
M

N L
G
N J

K H F
I

– 52 –
 3 Main switch
4 Battery EAS00780
R/B L/W O B G/W
A
R W/R W/G W/B B/Y
5 Main fuse (including head-
Br R R Br
light and brake light)
R R O O9 signal,
I Ancillary fuse (turn
W/R W/R

WIRE HARNESS
SUB-WIRE 1 W/G W/G B
horn, speedometer, auxil-
HARNESS W/G L/W
iary light, license0
plate light,
CIRCUIT DIAGRAM

B W R W/G W/G R
W W W/L W/R W/R W/G R
R/B
8 taillight)
W/B
L Y Y A R R R R G/W
M License plate light
R
B W W W
LIGHTING SYSTEM

W
R R
W W W
N Tail/brake light
W W R
SUB-WIRE B/Y
WIRE HARNESS 4 R R S Light switch
HARNESS
L/W L/B
3 B 5
C
2 X Auxiliary light
B R ON R Br Br R B
B
W W W B/Y
Y Headlight
OFF L/W
B R (GRAY)
Br R/B R/B R/W
(BLACK) 6 b Multifunction meter
Br
(BLACK) L/B A
(BLACK) B d High beam indicator light
Br B B B B B/Y B
ENGINE STOP
WIRE HARNESS A
SWITCH SUB LEAD B e Meter light
I R B
R R
Br/L
7

O Br/W
Br/L
Br/W Dg Br/L
Br/W G/W Sb
Ch
(BLACK)
Y P

– 53 –
Br Br/L L/B Br R/B Br W/B
Br/W
Br/W C C Br Br E Br Br (GREEN)
P Br Br/G L/B W/B Br
Br/B G/B Br/W Br R/B
Q B
Br/G P Y Br R/B
R S T U
N L K J F G
L R/W Sb
B B B B
B ^ Br Y R/W G/L

L/B G B L/B L/W (BLACK) (BLACK)

R P B
Br/B G/B Y Y G
B L R Sb G/W
Y Y W/B G/L
Ch Dg B R/B R/W
B L R Y Y G P Y Br Y Br W/B Br
R L Y Br
Ch G/L Br
B Dg Y B G L/B
P (BLACK) (BLACK) Sb G/W
L V P Y
Br/L V
Br
Y
b B
Y/B
LIGHTING SYSTEM

B
B G/L
B G/W
Y
c d
Y Y
Dg V Br/L Br/L G/W
B Y/B Ch Dg Ch Dg W Y G
W Br/L Y Br/L
Br/L Br
Br/L W
H D C
Ch P ] \ [ Z X Y N M
e Y L Br/L Y
Y G G Y
a B Ch B Ch B B
Dg B B Dg B B
(BLACK) (BLACK) L B
ELEC

(BLACK)
(BLACK)
B B B B B
Ch B B Dg Ch B Dg B B B
B Br/L
–

(BLACK) (BLACK)
+
 – +
LIGHTING SYSTEM ELEC
EAS00788
2. The high beam indicator light fails to come
CHECKING THE LIGHTING SYSTEM
on.
1. The headlight fails to come on.
1. Voltage
1. Headlight bulb and socket
• Connect the pocket tester (DC 20 V) to the
• Check the headlight bulb and socket for
meter assembly coupler (wire harness
continuity.
side) as shown.
• Are the headlight bulb and socket OK?
Positive tester probe → yellow 1
YES NO Negative tester probe → black 2

Replace the head-

light bulb, socket or
both.
P W Br Y/B V Y
2. Voltage
• Connect the pocket tester (DC 20 V) to the Ch Br/L Br/L B Dg Y
headlight coupler as shown. 2 1
È When the light switch is set to “ ”. • Set the main switch to “ON”.
É When the light switch is set to “ ”. • Start the engine.
Positive tester probe → • Set the light switch to “ ”.
yellow 1 or green 2 • Measure the voltage (DC 12 V) of yellow
Negative tester probe → black 3 1 on the meter assembly coupler (wire
harness side).
• Is the voltage within specification?
É
YES NO
2 1
DC 20V

+ G Y
B
Replace the meter The wiring circuit
È assembly. from the main switch
3
to the meter assem-
bly coupler is faulty
• Set the main switch to “ON”. and must be re-
• Start the engine. paired.
• Set the light switch to “ ” or “ ”.
• Measure the voltage (DC 12 V) of yellow
1 (green 2) on the headlight coupler.
• Is the voltage within specification?

YES NO

This circuit is OK. The wiring circuit

from the main switch
to the headlight cou-
pler is faulty and
must be repaired.

– 54 –
 – +
LIGHTING SYSTEM ELEC
EAS00789 EAS00791
3. The meter light fails to come on. 4. The auxiliary light fails to come on.

1. Voltage 1. Auxiliary light bulb and socket

• Connect the pocket tester (DC 20 V) to the • Check the auxiliary light bulb and socket
meter assembly coupler (wire harness for continuity.
side) as shown. • Are the auxiliary light bulb and socket OK?
Positive tester probe → brown/blue 1 YES NO
Negative tester probe → black 2

Replace the auxiliary

light bulb, socket or
both.

P W Br Y/B V Y
2. Voltage

Ch Br/L Br/L B Dg Y • Connect the pocket tester (DC 20 V) to the

auxiliary light connector (wire harness
1 2 side) as shown.
• Set the main switch to “ON”. Positive tester probe → brown/blue 1
• Measure the voltage (DC 12 V) of brown/ Negative tester probe → black 2
blue 1 on the meter assembly coupler
(wire harness side). 1
• Is the voltage within specification?
Br Br/L
YES NO

Y G G Y
Replace the meter The wiring circuit B B
assembly. from the main switch
to the meter assem- 2
bly coupler is faulty
• Set the main switch to “ON”.
and must be
• Measure the voltage (DC 12 V) of brown/
repaired.
blue 1 on the auxiliary light connector
(wire harness side).
• Is the voltage within specification?

YES NO

This circuit is OK. The wiring circuit

from the main switch
to the auxiliary light
connector is faulty
and must be
repaired.

– 55 –
 – +
LIGHTING SYSTEM ELEC
EAS00792
5. The license plate light fails to come on.

1. License plate light bulb and socket

• Check the license plate light bulb and
socket for continuity.
• Are the license plate light bulb and socket
OK?

YES NO

Replace the license

plate light bulb,
socket or both.

2. Voltage
• Connect the pocket tester (DC 20 V) to the
license plate light coupler (wire harness
side) as shown.
Positive tester probe → brown/blue 1
Negative tester probe → black 2

L B B Br/L

2 1

• Set the main switch to “ON”.

• Measure the voltage (DC 12 V) of brown/
blue 1 on the license plate light coupler
(wire harness side).
• Is the voltage within specification?

YES NO

This circuit is OK. The wiring circuit

from the main switch
to the license plate
light coupler is faulty
and must be
repaired.

– 56 –
 A
R/B L/W O B G/W
EAS00793
R W/R W/G W/B B/Y

Br R R Br
R R O O 9
W/R W/R

WIRE HARNESS
SUB-WIRE 1 W/G W/G B
HARNESS W/G L/W
0
B W R W/G W/G R
R/B
CIRCUIT DIAGRAM

W W W/L W/R W/R W/G R 8

W/B
L Y Y A R R R R G/W
R
B W W W
W
R R
W W W
W W R
SUB-WIRE B/Y
WIRE HARNESS 4 R R
HARNESS
SIGNALING SYSTEM

L/W L/B
3 B 5
C
2
B R ON R Br Br R B
B
W W W B/Y
OFF L/W
B R (GRAY)
Br R/B R/B R/W
(BLACK) 6
Br
(BLACK) L/B A
(BLACK) B
Br B B B B B/Y B
ENGINE STOP
WIRE HARNESS A
SWITCH SUB LEAD B
I R B
R R
Br/L
7

O Br/W
Br/L
Br/W Dg Br/L
Br/W G/W Sb
Ch
(BLACK)
Y P
Br Br/L L/B Br R/B Br W/B

– 57 –
Br/W
Br/W C C Br Br E Br Br (GREEN)
P Br Br/G L/B W/B Br
Br/B G/B Br/W Br R/B
Q B
Br/G P Y Br R/B
R S T U
N L K J F G
L R/W Sb
B B B B
B ^ Br Y R/W G/L

L/B G B L/B L/W (BLACK) (BLACK)

R P B
Br/B G/B Y Y G
B L R Sb G/W
Y Y W/B G/L
Ch Dg B R/B R/W
B L R Y Y G P Y Br Y Br W/B Br
R L Y Br
Ch G/L Br
B Dg Y B G L/B
P (BLACK) (BLACK) Sb G/W
L V P Y
Br/L V
Br
Y
b B
Y/B
SIGNALING SYSTEM

B
B G/L
B G/W
Y
c d
Y Y
Dg V Br/L Br/L G/W
B Y/B Ch Dg Ch Dg W Y G
W Br/L Y Br/L
Br/L Br
Br/L W
H D C
Ch P ] \ [ Z X Y N M
Y L Br/L Y
e Y G G Y
a B Ch B Ch B B
Dg B B Dg B B
ELEC

(BLACK) (BLACK) L B
(BLACK)
(BLACK)
B B B B B
Ch B B Dg Ch B Dg B B B
–

B Br/L
(BLACK) (BLACK)
+
 – +
SIGNALING SYSTEM ELEC
3 Main switch
4 Battery
5 Main fuse (including headlight and brake light)
B Starting circuit cut-off relay
C Drive select lever switch
D Neutral switch
F Neutral indicator light
G Reverse indicator light
H Reverse switch
I Ancillary fuse (turn signal, horn, speedometer, auxiliary light, license plate light, taillight)
J Rear brake light switch
K Front brake light switch
N Tail/brake light
O Turn signal relay
Q Turn signal switch
R Hazard switch
T Horn switch
V Horn
Z Rear turn signal light (right)
[ Rear turn signal light (left)
\ Front turn signal light (right)
] Front turn signal light (left)
_ Speed sensor
b Multifunction meter
c Turn signal indicator light

– 58 –
 – +
SIGNALING SYSTEM ELEC
EAS00796
CHECKING THE SIGNALING SYSTEM 3. Horn
1. The horn fails to sound. • Disconnect the black lead at the horn ter-
minal.
1. Horn switch
• Connect a jumper lead 1 to the horn ter-
• Check the horn switch for continuity. minal and ground.
Refer to “CHECKING THE SWITCH”. • Set the main switch to “ON”.
(Manual No.: 3GD-AE6) • Push the horn switch.
• Is the horn switch OK? • Does the horn sound?
YES NO

Replace the handle-

bar switch.

2. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector as shown.
Positive tester probe → pink 1 YES NO
Negative tester probe → ground
The wiring circuit Replace the horn.
from the horn termi-
nal to ground is faulty
and must be re-
paired.

• Set the main switch to “ON”.

• Push the horn switch.
• Measure the voltage (DC 12 V) of pink at
the horn terminal.
• Is the voltage within specification?

YES NO

The wiring circuit

from the main switch
to the horn connector
is faulty and must be
repaired.

– 59 –
 – +
SIGNALING SYSTEM ELEC
EAS00799
2. The turn signal light, turn signal indicator 4. Voltage
light or both fail to blink. • Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness
1. Turn signal light bulb and socket
side) as shown.
• Check the turn signal light bulb and socket
Positive tester probe → brown/blue 1
for continuity.
Negative tester probe → ground
• Are the turn signal light bulb and socket
OK?

YES NO

Br/W
Replace the turn sig-
nal light bulb, socket Br/L

or both. 1

2. Turn signal switch

• Set the main switch to “ON”.
• Check the turn signal switch for continuity. • Measure the voltage (DC 12 V) on brown/
Refer to “CHECKING THE SWITCH”. blue 1 at the turn signal relay coupler
(Manual No.: 3GD-AE6) (wire harness side).
• Is the turn signal switch OK? • Is the voltage within specification?
YES NO YES NO

Replace the handle- The wiring circuit

bar switch. from the main switch
to the turn signal re-
3. Hazard switch lay coupler is faulty
and must be re-
• Check the hazard switch for continuity.
paired.
Refer to “CHECKING THE SWITCH”.
(Manual No.: 3GD-AE6)
• Is the hazard switch OK?

YES NO

Replace the handle-

bar switch.

– 60 –
 – +
SIGNALING SYSTEM ELEC
5. Voltage È É

• Connect the pocket tester (DC 20 V) to the

turn signal relay coupler (wire harness
side) as shown.
Ch B B Dg
Positive tester probe → brown/white 1
Negative tester probe → ground Ch B B Dg
1 2

Ê Ë

Br/W

Br/L
1 Ch B Dg B

Ch B Dg B
• Set the main switch to “ON”. 1 2
• Measure the voltage (DC 12 V) on brown/
white 1 at the turn signal relay coupler Ì
(wire harness side).
• Is the voltage within specification?

YES NO
P W Br Y/B V Y

The turn signal relay Ch Br/L Br/L B Dg Y

is faulty and must be
1 2
replaced.
• Set the main switch to “ON”.
6. Voltage • Set the turn signal switch to “ ” or “ ”.
• Measure the voltage (DC 12 V) of the
• Connect the pocket tester (DC 20 V) to the chocolate 1 or dark green 2 at the turn
turn signal light coupler or meter assembly signal light coupler or meter assembly
coupler (wire harness side) as shown. coupler (wire harness side).
È Front turn signal light assembly (left) • Is the voltage within specification?
É Front turn signal light assembly (right)
Ê Rear turn signal light assembly (left) YES NO
Ë Rear turn signal light assembly (right)
Ì Meter assembly
Replace the meter The wiring circuit
Left turn signal light
assembly. from the turn signal
Positive tester probe → chocolate 1
switch to the turn sig-
Negative tester probe → ground
nal light coupler or
Right turn signal light meter assembly cou-
Positive tester probe → dark green 2 pler is faulty and
Negative tester probe → ground must be repaired.

– 61 –
 – +
SIGNALING SYSTEM ELEC
EAS00806
3. The speedometer fails to operate. 2. Voltage
• Connect the pocket tester (DC 20 V) to the
1. Speed sensor
meter assembly coupler (wire harness
• Connect the pocket tester (DC 20 V) to the side) as shown.
speed sensor coupler as shown.
Positive tester probe → brown/blue 1
Positive tester probe → blue 1 Negative tester probe → black 2
Negative tester probe → black 2

P W Br Y/B V Y
R B L
Ch Br/L Br/L B Dg Y
R B L
1 2
2 1
• Set the main switch to “ON”.
• Set the main switch to “ON”. • Measure the voltage (DC 12 V) of brown/
• Elevate the rear wheels and slowly rotate blue 1 on the meter assembly coupler
them. (wire harness side).
NOTE: • Is the voltage within specification?
• Rotate the rear wheels by hand.
YES NO
• The voltage reading should drop to 0 as the
speed sensor magnet approaches the
speed sensor È. Replace the meter The wiring circuit
assembly. from the main switch
• Measure the voltage (DC 5 V) of blue and to the meter assem-
black. With each full rotation of the rear bly coupler is faulty
wheels, the voltage reading should cycle and must be re-
from 0 V to 4.6 V to 0 V to 4.6 V. paired.
Voltage (V) 1 cycle (rotation)

4.6

0
È È Rotation of rear
sprocket

• Does the voltage reading cycle correctly?

YES NO

Replace the speed

sensor.

– 62 –
YFM350R-W 2006 WIRING DIAGRAM
1 A.C. magneto COLOR CODE
2 Rectifier/regulator B ............ Black
3 Main switch Br........... Brown
4 Battery Ch.......... Chocolate
5 Main fuse (including headlight and brake light) Dg.......... Dark green
6 Starter relay G ........... Green
7 Starter motor L ............ Blue
8 C.D.I. unit O ........... Orange
9 Ignition coil P ............ Pink
0 Spark plug R............ Red
A Clutch switch Sb .......... Sky blue
B Starting circuit cut-off relay V ............ Violet
C Drive select lever switch W ........... White
D Neutral switch Y ............ Yellow
E Indicator light assembly B/Y ........ Black/Yellow
F Neutral indicator light Br/B ....... Brown/Black
G Reverse indicator light Br/G ....... Brown/Green
H Reverse switch Br/L........ Brown/Blue
I Ancillary fuse (turn signal, horn, speedometer, Br/W ...... Brown/White
auxiliary light, license plate light, taillight) G/B ........ Green/Black
J Rear brake light switch G/L ........ Green/Blue
K Front brake light switch G/W ....... Green/White
L Engine stop switch L/B ......... Blue/Black
M License plate light L/W ........ Blue/White
N Tail/brake light R/B ........ Red/Black
O Turn signal relay R/W ....... Red/White
P Handlebar switch W/B ....... White/Black
Q Turn signal switch W/G ....... White/Green
R Hazard switch W/L ........ White/Blue
S Light switch W/R ....... White/Red
T Horn switch Y/B ........ Yellow/Black
U Start switch
V Horn
W Headlight assembly
X Auxiliary light
Y Headlight
Z Rear turn signal light (right)
[ Rear turn signal light (left)
\ Front turn signal light (right)
] Front turn signal light (left)
^ Speed sensor
a Meter assembly
b Multifunction meter
c Turn signal indicator light
d High beam indicator light
e Meter light
YFM350R-W 2006 YFM350R-W 2006
WIRING DIAGRAM SCHÉMA DE CÂBLAGE

R/B L/W O B G/W

A
R W/R W/G W/B B/Y

Br R R Br
R R O O 9
W/R W/R

WIRE HARNESS
SUB-WIRE 1 W/G W/G B
HARNESS W/G L/W
0
B W R W/G W/G R
W W W/L W/R W/R W/G R
R/B
W/B
8
L Y Y A R R R R G/W
R
B W W W
W
R R
W W W
W W R
WIRE HARNESS
SUB-WIRE
HARNESS
4 R R
B/Y

2 3 B 5 L/W L/B

C
B R ON R Br Br R B
W W W B
OFF L/W
B/Y
B R (GRAY)
Br R/B R/B R/W
(BLACK) 6
(BLACK) (BLACK)
Br
B
L/B A
Br B B B B B/Y B
ENGINE STOP
WIRE HARNESS SWITCH SUB LEAD A B
I R B

Br/L
R R
7

O Br/W
Br/L
Br/W Dg Br/L
Br/W
(BLACK) G/W Sb
Y P Ch
Br Br/L L/B Br R/B Br W/B
Br/W

P Br/W
Br Br/G L/B
C C Br Br E Br Br W/B Br (GREEN)
Br/B G/B Br/W Q Br R/B
B
Br/G P Y
R S T U Br R/B

N L K J F G
L R/W Sb

B ^ Br Y
B B B B
R/W G/L

L/B G B L/B L/W (BLACK) (BLACK)

R P B
Br/B G/B Y Y G
B L R Sb G/W
Y Y W/B G/L
Ch Dg B R/B R/W
B L R Y Y G P Y Br Y Br W/B Br
R L Y Br
Ch G/L Br
B Dg Y B G L/B
P (BLACK) (BLACK) Sb G/W
L V P Y
Br/L V
Br

Y/B
b B
Y

B
B G/L
B G/W
Y
c d
Y Y
Dg V Br/L Br/L G/W
B Y/B
W
Ch Dg Ch Dg W Y G
Br/L Y Br/L
Br/L Br
H D C
Br/L
Ch
W
P ] \ [ Z X Y N M
e Y G G Y
Y L Br/L Y

a B Ch
Dg B
B Ch
B Dg B B
B B
(BLACK) (BLACK) L B
(BLACK)
(BLACK)
B B B B B
Ch B B Dg Ch B Dg B B B
B Br/L
(BLACK) (BLACK)