lock YAMAHA WR 250F 2016 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2016, Model line: WR 250F, Model: YAMAHA WR 250F 2016Pages: 428, PDF Size: 14.13 MB
Page 68 of 428
TIGHTENING TORQUES
2-15
TIP
Exhaust pipe nut
First temporarily tighten nuts to 13 Nm (1.3 m·kgf, 9.4 ft·lbf). Then retighten them to 20 Nm (2.0 m·kgf,
14 ft·lbf).Clutch boss nut M16 1 75 Nm (7.5 m·kgf, 54 ft·lbf)Use a
lock
washer.
Drive sprocket nut M18 1 75 Nm (7.5 m·kgf, 54 ft·lbf)Use a
lock
washer.
Segment
M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Shift guide bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Stopper lever bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Shift pedal bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Rotor nut
M12 1 65 Nm (6.5 m·kgf, 47 ft·lbf)
Stator screw
M5 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankshaft position sensor bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Damper assembly cover bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Starter clutch bolt
M6 6 16 Nm (1.6 m·kgf, 12 ft·lbf)
Starter motor bolt
M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Coolant temperature sensor
M10 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Neutral switch bolt
M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Intake air temperature sensor screw
M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rectifier/regulator bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ECU bolt
M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Ignition coil bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle position sensor screw
M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Intake air pressure sensor screw
M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf) ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
LT
LT
LT
LT
LT
LT
Page 69 of 428
TIGHTENING TORQUES
2-16
EAS2GB7067CHASSIS TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
Outer tube and upper bracket bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Outer tube and lower bracket bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Upper bracket and steering stem nut M24 1 145 Nm (14.5 m·kgf, 105 ft·lbf)
Upper handlebar holder bolt M8 4 28 Nm (2.8 m·kgf, 20 ft·lbf)
Lower handlebar holder nut M10 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Engine stop switch screw M3 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Start switch screw M4 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Lower ring nut M28 1 See TIP.
Outer tube and damper assembly M51 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Inner tube and adjuster M22 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
Damper assembly and base valve M42 2 28 Nm (2.8 m·kgf, 20 ft·lbf)
Damper assembly adjuster M12 2 29 Nm (2.9 m·kgf, 21 ft·lbf)
Bleed screw (front fork) and base
valveM5 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Front fork protector bolt M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fork protector and brake hose
holder nutM6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle grip cap screw M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Clutch lever holder bolt M6 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Clutch lever nut M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front brake master cylinder holder
boltM6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake master cylinder reser-
voir cap screwM4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Front brake lever pivot bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever pivot nut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever position locknut M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front brake hose holder and lower
bracket boltM6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front brake caliper bolt M8 2 23 Nm (2.3 m·kgf, 17 ft·lbf)
Front brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front wheel axle nut M16 1 90 Nm (9.0 m·kgf, 65 ft·lbf)
Front wheel axle pinch bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
LT
Page 70 of 428
TIGHTENING TORQUES
2-17
Front brake disc bolt M6 6 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Rear brake disc bolt M6 6 14 Nm (1.4 m·kgf, 10 ft·lbf)
Footrest bracket bolt M10 4 55 Nm (5.5 m·kgf, 40 ft·lbf)
Sidestand bolt M10 1 25 Nm (2.5 m·kgf, 18 ft·lbf)
Rear brake pedal bolt M8 1 26 Nm (2.6 m·kgf, 19 ft·lbf)
Rear brake pedal position locknut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake master cylinder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake master cylinder reservoir
cap boltM4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rear brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Rear brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Rear brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear wheel axle nut M22 1 125 Nm (12.5 m·kgf, 90 ft·lbf)
Drive chain puller adjust bolt and
locknutM8 2 21 Nm (2.1 m·kgf, 15 ft·lbf)
Rear wheel sprocket nut M8 6 50 Nm (5.0 m·kgf, 36 ft·lbf)
Nipple (spoke) — 72 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear brake disc cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake caliper protector bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Engine mounting bolt (upper side) M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf)
Engine mounting bolt (front side) M10 1 55 Nm (5.5 m·kgf, 40 ft·lbf)
Engine mounting bolt (lower side) M10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Engine bracket bolt (upper side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Engine bracket bolt (front side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Rear frame and frame bolt M8 4 38 Nm (3.8 m·kgf, 27 ft·lbf)
Engine guard bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pivot shaft and nut M16 1 85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear shock absorber assembly up-
per boltM10 1 56 Nm (5.6 m·kgf, 41 ft·lbf)
Rear shock absorber assembly low-
er boltM10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Rear shock absorber locknut M60 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Relay arm bolt (swingarm side) M14 1 70 Nm (7.0 m·kgf, 51 ft·lbf)
Connecting arm bolt (relay arm side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Connecting arm bolt (frame side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Swingarm and brake hose holder
screwM5 4 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Drive chain tensioner bolt (upper
side)M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf) ITEMThread
sizeQ’ty TIGHTENING TORQUES RemarksLT
LT
LT
Page 85 of 428
CABLE ROUTING DIAGRAM
2-32
1. Clutch cable
2. Throttle cable (return)
3. Throttle cable (pull)
4. Engine stop switch lead
5. Coupler for connecting optional part
6. Engine stop switch coupler
7. Rectifier/regulator coupler
8. AC magneto lead
9. Starter knob/idle screw
10. Starter motor lead
11. Radiator fan fuse
12. Taillight
13. Headlight relay (yellow tape)
14. Starting circuit cut-off relay (no identification
tape)
15. Diode
16. Holder plate
17. Left of the vehicle:radiator fan motor relay (blue
tape)
Right of the vehicle:main relay (red tape)
18. Neutral switch lead
19. Engine bracket
20. Front engine bracket
21. Plastic locking tie
22. Radiator hose
23. Neutral switch coupler
24. Crankshaft position sensor coupler
25. Tension arm
26. Wire harness
27. Tank rail
28. Rectifier/regulator
29. Rectifier/regulator bracket
30. Rear frame
31. Side cover 5
32. Crankcase cover
33. Crankcase
34. Lead holder
35. Frame
A. Pass the engine stop switch lead between the
frame and the cable holder.
B. Insert the coupler for connecting optional part into
the connector, and fix it to the bracket.
C. Insert and fix the engine stop switch coupler to
the bracket.
D. Insert and fix the rectifier/regulator coupler to the
bracket.
E. Pass the AC magneto lead to the front of the ve-
hicle beyond the starter knob/idle screw and to
the rear of the vehicle beyond the radiator. No
pinch is allowed between the radiator and the
tension arm.
F. Place the rear grommet of the starter motor lead
matching the rear end of the side cover.
G. Insert the radiator fan motor fuse into the protru-
sion of the holder plate.
H. Place the diode on top of the rear fender on the
inner side of the rear frame.
I. Bring the neutral switch lead into line with the
crankcase cover with no sag allowed.
J. Route the AC magneto lead under the starter
clutch cover.
K. Pass the neutral switch lead to the inside of the
front engine bracket (the side of the vehicle).
L. Insert the plastic locking tie into the bracket hole
and clamp the clutch cable. Clamp it so that the
lock of the plastic locking tie faces downward,
and then cut off the end of the plastic locking tie.
M. Pass the clutch cable with no downward sag al-
lowed.N. Place the grommet of the clutch cable so that it
contacts the radiator hose. Route the clutch cable
outside the neutral switch lead, AC magneto lead
and starter motor lead.
O. Route each lead so that the leads are not pinched
between the radiator hose and the frame.
P. 40 mm (1.57 in)
Q. Clamp the clutch cable, AC magneto lead, neu-
tral switch lead and starter motor lead by the plas-
tic locking tie. Make sure that they are clamped at
the positioning tapes in the clutch cable and the
starter motor lead. Make the lock on the plastic
locking tie face the front of the vehicle, and cut
the end.
R. Clamp the starter motor lead to the inside of the
tension arm with a plastic locking tie. Clamp it so
that the lock of the plastic locking tie faces up-
ward and outward, and do not cut off the end of
the plastic locking tie. Route the lead so that there
is no slack at the bottom from the clamp position
onwards.
S. After connecting the neutral switch coupler, at-
tach the coupler cover.
T. After connecting the crankshaft position sensor
coupler, attach the coupler cover.
U. Pass the rectifier/regulator lead to the inside of
the tension arm (the side of the vehicle).
V. Pass the main harness to the front of the radiator
hose (the front of the vehicle), and to the inside of
the clutch cable (the side of the vehicle).
W. Pass the engine stop switch lead between the
coupler for connecting optional part and the tank
rail, with the lead on the main harness side facing
the top of the vehicle.
X. Insert the starter motor lead completely into the
end of the side cover 5.
Y. Clamp the clutch cable at the front of the lead (the
front of the vehicle).
Z. Insert the clip of the plastic locking tie into the
frame. Face the lock of the plastic locking tie for-
ward, and then cut off the end.
Page 91 of 428
CABLE ROUTING DIAGRAM
2-38
1. Battery negative lead
2. Fuel hose
3. Fuel pump coupler
4. Fuel pump lead
5. Resistor
6. Resistor coupler
7. Battery positive lead
8. Lean angle sensor
9. Starter motor lead
10. Radiator fan motor relay (blue tape)
11. Main relay (red tape)
12. Wire harness
13. Ground lead coupler
14. Starter relay coupler
15. Starter relay
16. Cross member
17. Diode
18. Taillight lead
19. Clamp
20. Fuel tank
21. Damper
22. Rear frame
23. Side cover 6
24. Plastic locking tie
A. After connecting the fuel pump coupler, attach
the coupler cover.
B. Pass the fuel hose to the front of the battery.
C. Route the resistor lead to the outside of the leads.
D. Connect the battery positive lead to the starter re-
lay terminal (in the left side of the vehicle).
E. Insert the protruding end of the wire harness into
the battery bracket hole and holder plate hole.
F. After connecting the negative lead coupler, place
it on the right side of the battery.
G. After installing the plastic cover to the starter re-
lay, connect the starter relay coupler.
H. Route the diode under the cross member and
place it on top of the rear fender.
I. Secure the two ends of the taillight coupler with
the starter motor lead.
J. Route the taillight lead so that it does not slack at
the rear of the vehicle.
K. Clamp the taillight lead and insert the clip into the
rear fender. Clamp it so that the lock faces in-
ward, and then cut off the excess end.
L. Route the battery positive lead under the cross
member.
M. Lower end of the rear frame
N. Clamp it so that the lock of the plastic locking tie
faces downward, insert the end into the rear
frame and side cover 6, and then cut off the ex-
cess end. After cutting off the excess end, make
sure that the plastic locking tie does not protrude
from the lower end of the rear frame.
O. Clamp it so that the lock of the plastic locking tie
faces downward, and then pass the end between
the fuel hose and rear frame.
P. Clamp the wire harness at the position of the
white tape.
Page 112 of 428
ENGINE
3-12
EAS2GB7087CHECKING THE COOLANT CIRCULATORY
SYSTEM FOR LEAKS
1. Check:
• Coolant level
2. Install:
• Radiator cap tester “1”
• Adapter “2”
3. Activate the tester to apply the test pressure.
ECA
NOTICE
• Do not apply such a high pressure as ex-
ceeds the test pressure.
• Make sure that a checkup after the cylin-
der head gasket is replaced is made after 3
minutes of warm-up.
• Make sure that coolant is filled up to the
upper level beforehand.
4. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres-
sure value Correct.
• Radiator
• Radiator hose connections
Coolant leaks Correct or replace.
• Radiator hoses
Bulges Replace
EWA
WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.
EAS2GB7088ADJUSTING THE CLUTCH LEVER FREE
PLAY
1. Check:
• Clutch lever free play “a”
Out of specification Regulate.
2. Adjust:
• Clutch lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar side
a. Turn the adjuster “1” in direction “a” or “b”
until the specified clutch lever free play is ob-
tained.
TIP
If the clutch lever free play cannot be obtained
on the handlebar side, use the adjuster on the
clutch cable side.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Clutch cable side
a. Slide the clutch cable cover.
b. Loosen the locknut “1”. Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
Test pressure value
196 kPa (1.96 kg/cm
2, 27.9 psi)
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
Direction “a”
Clutch lever free play is increased.
Direction “b”
Clutch lever free play is decreased.
a b
1
Page 113 of 428
ENGINE
3-13
c. Turn the adjuster “2” in direction “a” or “b”
until the specified clutch lever free play is ob-
tained.
d. Tighten the locknut “1”.
e. Return the clutch cable cover to its original
position.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GB7089ADJUSTING THE THROTTLE GRIP FREE
PLAY
TIP
Prior to adjusting throttle grip free play, the en-
gine idling speed should be adjusted.
1. Check:
• Throttle grip free play “a”
Out of specification Regulate.2. Adjust:
• Throttle grip free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjuster “2” until the specified free
play is obtained.
c. Tighten the locknut.
EWA
WARNING
After adjusting the throttle grip free play,
turn the handlebar to the right and to the left
to ensure that this does not cause the en-
gine idling speed to change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GB7090LUBRICATING THE THROTTLE CABLE
1. Remove:
• Cover (throttle cable cap) “1”
• Cover (grip cap) “2”
• Throttle grip cap “3” Direction “a”
Clutch lever free play is increased.
Direction “b”
Clutch lever free play is decreased.
Locknut
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)
T R..
1
2a
b
Direction “a”
Throttle grip free play is increased.
Direction “b”
Throttle grip free play is decreased.
1 2
b
a
Page 118 of 428
ENGINE
3-18
8. Install:
• Oil filler cap
9. Check:
• Oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-16.
10.Check:
• Engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil pressure check bolt
“1”.
EWA
WARNING
When the engine is started with the check
bolt removed, oil will spout; therefore, al-
ways loosen it before the checkup.
Start the engine and keep it idling until oil
starts to seep from the oil pressure check
bolt.
EWA
WARNING
Always keep the engine idling speed during
the checkup without increasing the engine
speed.
ECA
NOTICE
If no engine oil seeps out after one minute,
immediately turn the engine off so it will not
seize.
b. If no engine oil seeps out, check the engine
oil for leaks, and the engine oil passage and
the oil pump for damage.
c. Check the oil pressure again.
d. Tighten the oil pressure check bolt.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GB7098ADJUSTING THE ENGINE IDLING SPEED
TIP
• Because the air pressure is lower at high alti-
tudes, the air-fuel mixture will become richer.
If the idling speed is low, turn the starter knob/
idle screw a few clicks counterclockwise to in-
crease the speed before the adjustment.
• Before adjusting the engine idling speed,
make sure that the air filter element is not
clogged, the engine compression is proper,
and the throttle grip free play is proper.
• Adjust the engine idling speed with the starter
knob/idle screw pushed in completely.
1. Start the engine, and warm this up until the
oil has reached the specified temperature.
2. Attach the pocket tester with temperature
probe “1” to the oil drain bolt.
3. Install:
• Digital tachometer
TIP
Get the high tension cord “1” of the ignition coil
pinched in the detector “a” of the digital tachom-
eter.
Oil pressure check bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
T R..
Oil temperature
70.0–80.0 °C (158.00–176.00 °F)
Digital tachometer
90890-06760
Digital tachometer
YU-39951-B
1
1 1
a a
Page 119 of 428
ENGINE
3-19
4. Measure:
• Engine idling speed
Out of specification Regulate.
5. Adjust:
• Engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the starter knob/idle screw “1” in the di-
rection of “a” or “b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ADJUSTING THE VALVE CLEARANCE
TIP
• This section is intended for those who have
basic knowledge and skill concerning the ser-
vicing of Yamaha motorcycles (e.g., Yamaha
dealers, service engineers, etc.). Those who
have little knowledge and skill concerning ser-
vicing are requested not to undertake inspec-
tion, adjustment, disassembly, or reassembly
only by reference to this manual. It may lead
to servicing trouble and mechanical damage.
• Make sure that the valve clearance is
checked or adjusted while the engine is cold
(at room temperature).
• While the valve clearance is checked or ad-
justed, make sure that the piston is positioned
in the top dead center (TDC).1. Remove:
• Seat
• Side cover (left/right)
• Air scoop (left/right)
Refer to “GENERAL CHASSIS” on page 5-
1.
• Fuel tank
Refer to “FUEL TANK” on page 8-1.
•ECU
2. Remove:
• Spark plug
• Cylinder head cover
Refer to “CAMSHAFT” on page 6-11.
3. Remove:
• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
• O-ring
4. Check:
• Valve clearance
Out of specification Regulate.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise with a
wrench.
b. Align the top dead center (TDC) mark “a” on
the rotor with the alignment mark “b” on the
crankcase cover. Engine idling speed
1900–2100 r/min
Direction “a” Engine idling speed De-
creases.
Direction “b” Engine idling speed In-
creases.
1 b
a
Valve clearance (cold)
Intake
0.12–0.19 mm (0.0047–0.0075 in)
Exhaust
0.17–0.24 mm (0.0067–0.0094 in)
12
ab
Page 125 of 428
CHASSIS
3-25
EAS2GB7103CHECKING THE BRAKE HOSE
1. Check:
• Brake hose “1”
Cracks/damage/wear Replace.
2. Check:
• Brake hose clamp
Loose connection Tighten the clamp bolt.
3. Stand the vehicle upright and apply the front
brake and the rear brake several times.
4. Check:
• Brake hoses
Brake fluid leaks Replace the damaged
brake hose.
Refer to “FRONT BRAKE” on page 5-13.
Refer to “REAR BRAKE” on page 5-23.
EAS2GB7104ADJUSTING THE FRONT BRAKE
1. Check:
• Brake lever position “a”2. Remove:
• Brake lever cover
3. Adjust:
• Brake lever position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified brake lever position is
obtained.
c. Tighten the locknut.
EWA
WARNING
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance.
ECA
NOTICE
After adjusting the brake lever position,
make sure there is no brake drag.
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4. Install:
• Brake lever cover
A. Front
B. Rear
Brake lever position
95 mm (3.74 in)
Extent of adjustment
76–97 mm (2.99–3.82 in)
1
1
Direction “a”
Brake lever position is increased.
Direction “b”
Brake lever position is decreased.
Locknut
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
a
b
T R..