Yamaha TT-R90(R) Page 21 Instruction Manual Download | Manualshive

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GEN

INFO

SPECIAL TOOLS

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.

NOTE:

●

For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-” or “ACC-”.

●

For others, use part number starting with “90890-”.

Part number

Tool name/How to use

Illustration

YU-1083-A

90890-01084

90890-01085

Slide hammer set

Weight

Slide hammer bolt

These tools are used when removing or installing the

rocker arm shafts.

YU-1083-A

90890-01084
90890-01085

YU-1268, 90890-01268

Ring nut wrench

This tool is used when loosen the steering ring nut to

specification.

YU-1268

90890-01268

YU-3112-C, 90890-03112

Pocket tester

Use this tool to inspect the coil resistance, output

voltage and amperage.

YU-3112-C

90890-03112

YU-8036-B

90890-03113

Inductive tachometer

Engine tachometer

This tool is needed for observing engine rpm.

YU-8036-B

90890-03113

YM-4019, 90890-04019

Valve spring compressor

This tool is needed to remove and install the valve

assemblies.

YM-4019

90890-04019

YM-1300

90890-01294

Damper rod holder set

Damper rod holder

Use this tool to remove and install the damper rod.

YM-1300

90890-01294

YU-1304, 90890-01304

Piston pin puller set

This tool is used to remove the piston pin.

YU-1304

90890-01304

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Summary of Contents for TT-R90(R)

Page 1: ...TT R90R 5HN 28199 13 LIT 11626 16 27 OWNER S SERVICE MANUAL ...

Page 2: ......

Page 3: ...2002 by Yamaha Motor Corporation U S A 1st Edition April 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 27 ...

Page 4: ...r NOTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING READ THIS MANUAL CAREFULLY FOR INSTRUCTIONS ON HOW TO PROPERLY OPERATE THIS MACHINE ADULT INSTRUCTION AND SUPERVI SION ARE REQUIRED WEIGHT OF THE RIDER SHOULD NOT EXCEED 40 kg 88 lb ALWAYS WEAR A HELMET AND SUIT ABLE PROTECTIVE CLOTHING WH...

Page 5: ......

Page 6: ...l while smoking or in the vicinity of an open flame 2 If you should swallow some gasoline or inhale a lot of gasoline vapor or allow some gasoline to get in your eye s see your doctor immediately If any gasoline spills on your skin or clothing immediately wash it with soap and water and change your clothes 3 Always turn off the engine before leaving the machine unattended When parking the machine ...

Page 7: ...ak out of the car buretor or fuel tank 5 Never start your engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time Always operate your machine in an area with adequate ventilation 6 Always wear a helmet gloves boots trousers and jacket for motocross riding ...

Page 8: ...s is a one seater motorbike Don t give any person a ride 4 Let s learn how to ride properly Ask your parents for any question 5 When riding the machine be sure to wear the protective apparel as illustrated 1 Helmet 2 Goggles 3 Mouth guard 4 Gloves 5 Boots 6 Motocross pants 7 Long sleeved trainer ...

Page 9: ...alone 7 Before riding the machine ask your par ents to check the machine very carefully 8 Don t touch the areas shown or you ll get burnt in the hand 9 Don t touch rotating or moving parts 10 Before starting the engine be sure to shift the transmission into neutral ...

Page 10: ...en to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of six chapters General Information Specifications Regular inspection and adjustments Engine Chassis and Electrical 2 The table of contents is at the beginning of the manual Look over the general lay out of the book before finding th...

Page 11: ... start of each removal and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 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 3 The meanings of the symbol marks a...

Page 12: ...Tightening B Specified value Service limit C Engine speed D Resistance Ω Voltage V Electric current A Illustrated symbols E to H in the exploded diagram indicate grade of lubricant and loca tion of lubrication point E Apply engine oil F Apply molybdenum disulfide oil G Apply lightweight lithium soap base grease H Apply molybdenum disulfide grease Illustrated symbols I to J in the exploded diagrams...

Page 13: ...INDEX GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE ENG 4 CHASSIS CHAS 5 ELECTRICAL ELEC 6 GEN INFO INSP ADJ ...

Page 14: ...TING AND OPERATION 1 12 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 15 DEFINITION OF UNITS 2 15 CABLE ROUTING DIAGRAM 2 16 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PERIODIC MAINTENANCE AND LUBRICATION 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 2 ENGINE 3 3 CHASSIS 3 11 ELECTRICAL 3 19 ...

Page 15: ... 4 34 OIL PUMP 4 36 CDI MAGNETO 4 39 CRANKCASE AND CRANKSHAFT 4 41 SHIFT FORK SHIFT CAM AND TRANSMISSION 4 44 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT FORK 5 6 HANDLEBAR 5 9 STEERING 5 10 SWINGARM 5 11 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 CARBURETOR HEATING SYSTEM 6 6 NOISE REGULATION 6 9 MAINTENANCE RECORD 6 9 ...

Page 16: ...Throttle grip 4 Fuel tank cap 5 Kick starter 6 Fuel tank 7 Air cleaner 8 Rear brake pedal 9 Fuel cock 0 Starter lever choke A Drive chain B Shift pedal C Front fork NOTE The machine you have purchased may differ slightly from those shown in the following Designs and specifications are subject to change without notice 1 ...

Page 17: ... machine is stolen the authorities will need the number to search for and identify your machine EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the left side of the engine EC124000 MODEL LABEL The model label 1 is affixed to the frame und...

Page 18: ... Use proper tools and cleaning equip ment Refer to SPECIAL TOOLS sec tion 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During the machine disassembly clean all parts and place them in trays in the order of disassembly This will sp...

Page 19: ... EC134000 LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates 1 and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or num bers facing outward In other words the stamped lette...

Page 20: ...re etc on the connector 1 Disconnect Connector 2 Dry each terminal with an air bower 3 Connect and disconnect the connector two or three times 4 Pull the lead to check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the con nector 6 Connect Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE If there in n...

Page 21: ...ese tools are used when removing or installing the rocker arm shafts YU 1083 A 90890 01084 90890 01085 YU 1268 90890 01268 Ring nut wrench This tool is used when loosen the steering ring nut to specification YU 1268 90890 01268 YU 3112 C 90890 03112 Pocket tester Use this tool to inspect the coil resistance output voltage and amperage YU 3112 C 90890 03112 YU 8036 B 90890 03113 Inductive tachomete...

Page 22: ...90890 01184 Fork seal driver weight This tool is used to installing the oil seal YM 33963 90890 01184 YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components YM 34487 90890 06754 YM 33975 90890 01403 Ring nut wrench This tool is used when tighten the steering ring nut to specification YM 33975 90890 01403 YM 91042 90890 04...

Page 23: ...puller This tool is used to remove the rotor YU 33270 B 90890 01362 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 This sealant Bond is used for crankcase mating surface etc ACC QUICK GS KT 90890 85505 Part number Tool name How to use Illustration ...

Page 24: ...hifted by using the shift pedal 1 on the left side of the engine WARNING When starting out on the machine shift the transmission into 1st after pulling in the front brake lever and closing the throttle grip KICK STARTER WARNING Before starting the engine be sure to shift the transmission into neutral Rotate the kick starter 1 away from the engine Push the starter down lightly with your foot until ...

Page 25: ...is position fuel will not flow Always return the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding move the lever to this position FILL THE TANK AT THE FIRST OPPORTUNITY BE SURE TO SET THE LEVER TO ON AFTER REFUELIN...

Page 26: ...l tank above the bottom of the filler tube 1 as shown in the illustration or it may over flow when the fuel heats up later and expands a Fuel level CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to the engine internal parts such as valves piston rings and exhaust system etc Recommended fuel For USA AUS and NZ Unleaded gasoline only For CDN and EUROPE Regular...

Page 27: ...ection The starter choke should not be used The throttle should be opened slightly CAUTION See Engine break in Section prior to operating engine for the first time WARMING UP To get maximum engine life always warm up the engine before starting off Never acceler ate hard with a cold engine To see whether or not the engine is warm see if it responds to throttle normally with the stater choke turned ...

Page 28: ...gine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder forward inclined Displacement 89 cm3 5 43 cu in Bore stroke 47 0 51 8 mm 1 85 2 04 in Compression ratio 8 5 1 Compression pressure STD 1 000 kPa 10 kg cm2 145 psi at 1 000 r min Starting system Kick starter Lubrication system Wet sump Oil type or grade Engine oil For USA and CDN At 10 C 10 F or higher Å Yamalube 4 10W 30 or SA...

Page 29: ...0 6 0 7 mm 0 02 0 03 in Clutch type Wet multiple disc and centrifugal automatic Transmission Primary reduction system Spur gear Primary reduction ratio 67 18 3 722 Secondary reduction system Chain drive Secondary reduction ratio 35 14 2 500 Transmission type Constant mesh 3 speed Operation Left foot operation Gear ratio 1st 37 13 2 846 2nd 33 19 1 736 3rd 28 23 1 217 Chassis Frame type Double crad...

Page 30: ...uspension Front suspension Telescopic fork Rear suspension Swingarm monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 110 mm 4 33 in Rear wheel travel 93 mm 3 66 in Electrical Ignition system CDI magneto GENERAL SPECIFICATIONS ...

Page 31: ...ound limit 0 05 mm 0 0020 in Camshaft Drive method Chain drive left Cam dimensions Intake A 25 428 25 528 mm 1 0011 1 0050 in 25 398 mm 0 9999 in B 21 034 21 134 mm 0 8281 0 8320 in 21 004 mm 0 8269 in Exhaust A 25 286 25 386 mm 0 9955 0 9994 in 25 256 mm 0 9943 in B 21 047 21 147 mm 0 8286 0 8326 in 21 017 mm 0 8274 in Camshaft runout limit 0 03 mm 0 0012 in MAINTENANCE SPECIFICATIONS ...

Page 32: ...69 0 0989 in EX 1 49 3 07 mm 0 0587 0 1209 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 5 0 9 mm 0 0197 0 354 in EX 0 8 1 2 mm 0 0315 0 0472 in Stem outside diameter IN 4 475 4 490 mm 0 1762 0 1768 in 4 450 mm 0 1752 in EX 4 460 4 475 mm 0 1756 0 1762 in 4 435 mm 0 1746 in Guide inside diameter IN 4 500 4 51...

Page 33: ...in 26 9 mm 1 06 in EX 28 32 mm 1 11 in 26 9 mm 1 06 in Set length valve closed IN 24 2 mm 0 95 in EX 24 2 mm 0 95 in Compressed pressure installed IN 90 4 104 1 N 9 22 10 62 kg 20 33 23 41 lb EX 90 4 104 1 N 9 22 10 62 kg 20 33 23 41 lb Tilt limit IN 2 5 1 2 mm 2 5 0 05 in EX 2 5 1 2 mm 2 5 0 05 in Direction of winding top view IN Clockwise EX Clockwise Item Standard Limit MAINTENANCE SPECIFICATIO...

Page 34: ...3 000 mm 0 5117 0 5118 in 12 976 mm 0 5109 in Piston rings Top ring Type Barrel Dimensions B T 1 0 2 0 mm 0 04 0 08 in End gap installed 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 016 in Side clearance installed 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring Type Taper Dimensions B T 1 0 2 0 mm 0 04 0 08 in End gap installed 0 10 0 25 mm 0 004 0 010 in 0 4 mm 0 016 in Side clearance 0 020 0 0...

Page 35: ... Inner push cam push Push rod bending limit 0 5 mm 0 02 in Automatic centrifugal clutch Clutch in revolution 2 160 2 560 r min Clutch stall revolution 3 300 3 800 r min Shifter Shifter type Cam drum and guide bar Kick starter Type Ratchet type Kick clip friction force 5 8 14 7 N 0 59 1 50 kg 1 3 3 3 lb Carburetor I D mark 5HN1 01 Main jet M J 90 Main air jet M A J ø 1 1 Jet needle J N 4E9 2 Cutawa...

Page 36: ...pump type Trochoid type Tip clearance A or B 0 15 mm 0 0059 in 0 2 mm 0 0079 in Side clearance 0 13 0 18 mm 0 0051 0 0071 in 0 23 mm 0 0091 in Housing and rotor clearance 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Item Standard Limit MAINTENANCE SPECIFICATIONS ...

Page 37: ...oint cylinder head side M6 1 0 2 7 0 7 5 1 Carburetor joint carburetor side M6 1 0 2 7 0 7 5 1 Air filter case M6 1 0 2 7 0 7 5 1 Exhaust pipe M6 1 0 2 7 0 7 5 1 Exhaust pipe protector M6 1 0 7 7 0 7 5 1 Silencer M8 1 25 1 24 2 4 17 Silencer protector M5 0 8 2 4 0 4 2 9 Crankcase M6 1 0 9 10 1 0 7 2 Crankcase cover left M6 1 0 8 7 0 7 5 1 Drive sprocket cover M6 1 0 2 7 0 7 5 1 Crankcase cover rig...

Page 38: ...er travel 48 mm 1 89 in Spring free length 169 mm 6 65 in Fitting length 165 mm 6 5 in Spring rate STD K 45 6 N mm 4 65 kg mm 260 lb in Optional spring No Enclosed gas pressure 2 000 kPa 20 kg cm2 290 psi Swingarm Swingarm free play limit End 1 0 mm 0 04 in Side clearance 0 3 mm 0 01 in Wheel Front wheel type Spoke wheel Rear wheel type Spoke wheel Front rim size material 14 1 40 steel Rear rim si...

Page 39: ...in Front lining thickness 3 mm 0 12 in 2 mm 0 08 in Rear lining thickness 4 mm 0 16 in 2 mm 0 08 in Front shoe spring free length 32 7 mm 1 29 in Rear shoe spring free length 50 5 mm 1 99 in Brake lever and brake pedal Brake lever free play lever end 10 20 mm 0 39 0 79 in Brake pedal free play 10 20 mm 0 39 0 79 in Throttle grip free play 3 5 mm 0 12 0 20 in Item Standard Limit MAINTENANCE SPECIFI...

Page 40: ...4 0 29 Under bracket and front fork M10 1 25 2 33 3 3 24 Damper rod bolt M8 1 25 2 20 2 0 14 Handle crown and handlebar holder lower M10 1 25 2 40 4 0 29 Handlebar holder upper M6 1 0 4 13 1 3 9 4 Front brake cable holder and front fork M6 1 0 2 7 0 7 5 1 Steering ring nut M25 1 Refer to NOTE Fuel tank and fuel cock M6 1 0 2 7 0 7 5 1 Fuel tank and frame M6 1 0 2 7 0 7 5 1 Grab bar and frame M6 1 ...

Page 41: ...kup coil resistance color 248 372 Ω at 20 C 68 F Red White CDI unit model manufacturer 4GL 20 YAMAHA Ignition coil Model manufacturer 2JN 00 YAMAHA Minimum spark gap 6 mm 0 24 in Primary winding resistance 0 18 0 28 Ω at 20 C 68 F Secondary winding resistance 6 3 9 5 kΩ at 20 C 68 F Spark plug cap Type Resin Resistance 10 kΩ at 20 C 68 F MAINTENANCE SPECIFICATIONS ...

Page 42: ...y threads Com ponents should be at room temperature A Nut B Bolt TORQUE SPECIFICATION Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 4 3 11 22 40 61 94 A Distance between flats B Outside thread diameter EC230000 DEFINITION OF UNITS Unit Read Definition Measure mm cm millimeter centimeter 10 3 meter 10 2 meter Length Leng...

Page 43: ...0 Throttle cable A Cable holder B Fuel tank breather hose C Brake cable Å After fastening the starter cable CDI magneto lead wire harness and thermo switch lead cut off any excess from the plastic locking tie end ı Pass the ignition coil lead through the lead guide Ç Fasten the engine stop switch lead with the plastic bands Î Pass the brake cable through the cable guides 1 2 3 4 5 9 0 B A 6 C 1 Å ...

Page 44: ... Cable guide 0 Wire harness A Damper B CDI unit lead C CDI unit D Rectifier regulator lead E Rectifier regulator F Crankcase breather hose G Carburetor breather hose H Spark plug lead I Fuel hose J Starter cable K CDI magneto lead L Thermo switch A 1 2 3 4 5 6 7 89 0 A C E B F G H I 6 6 J L 5 H B 8 K 7 Å Ç Ç Ï Ì B B C C D D F F E ı Î D D B D A A B B B B C C C C E B D B D F F F F ...

Page 45: ...ten the CDI unit lead and rectifier regulator lead with the plastic clamp Align the tape on the rectifier regulator lead with the plastic clamp Ï After fastening the engine stop switch lead cut off any excess from the plastic locking tie end Ì Pass the CDI unit lead through the lead guide A 1 2 3 4 5 6 7 89 0 A C E B F G H I 6 6 J L 5 H B 8 K 7 Å Ç Ç Ï Ì B B C C D D F F E ı Î D D B D A A B B B B C...

Page 46: ...just if necessary Exhaust systems Check for leakage Retighten if necessary Replace gasket if necessary Engine oil Check oil level and vehicle for oil leakage Correct if necessary Change Warm engine before draining Clutch Check operation Adjust or replace cable Front brake Check operation Adjust brake lever free play and replace brake shoes if necessary Every ride Rear brake Check operation Adjust ...

Page 47: ...Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Sidestand Check operation Lubricate and repair if necessary Spark arrester 1 Clean Front fork Check operation and for oil leakage Correct accordingly Rear shock absorber assembly Check operation and shock absorber for oil leakage Replace shock absorber assembly if necessary Item Routine Page Brake Check operation ...

Page 48: ...ngine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage Throttle grip free play adjustment steps NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted Loosen the locknut 1 on throttle cable Turn the adjuster 2 in or out until the specified free play is obtained Turning in ...

Page 49: ...en squeezing the element Leaving too much of solvent in the ele ment may result in poor starting 4 Inspect Air filter element Damage Replace 5 Apply Foam air filter oil or engine mixing oil To the element NOTE Squeeze out the excess oil Element should be wet but not dripping 6 Install Air filter element 1 NOTE Align the projection a on the air filter case with the hole b in the air filter element ...

Page 50: ...proper level NOTE When inspecting the oil level do not screw the dipstick into the oil tank Insert the gauge lightly For USA and CDN CAUTION Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase Recommended oil At 10 C 10 F or higher Å Yamalube 4 10W 30 or SAE 10W 30 type SE SF motor oi...

Page 51: ...nce again NOTE Wait a few minutes until the oil settles before inspecting the oil level ENGINE OIL REPLACEMENT 1 Start the engine and warm it up for sev eral minutes and wait for five minutes 2 Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine 3 Place a suitable container under the engine 4 Remove Dipstick 1 Drain bolt with gasket 2 D...

Page 52: ...c oil change 0 8 L 0 70 Imp qt 0 85 US qt 7 Install Dipstick 8 Inspect Engine for oil leaks Oil level Refer to ENGINE OIL LEVEL INSPEC TION PILOT AIR SCREW ADJUSTMENT 1 Adjust Pilot air screw 1 Adjusting steps Screw in the pilot air screw until it is lightly seated Back out by the specified number of turns Pilot air screw 1 3 4 turns out ...

Page 53: ...check or adjust the valve clearance 1 Remove Air scoop right 1 Air filter case 2 2 Remove Spark plug Tappet cover intake side 1 Tappet cover exhaust side 2 Adjustment steps Adjust the pilot screw Refer to PILOT AIR SCREW ADJUST MENT section Turn the throttle stop screw 1 until the engine runs at the lowest possible speed To increase idle speed Turn the throttle stop screw 1 in a To decrease idle s...

Page 54: ... C on compression stroke Measure the valve clearance using a feeler gauge 1 Out of specification Adjust clearance Adjustment steps Loosen the locknut 1 Turn the adjuster 3 in or out with the valve adjusting tool 2 until specified clear ance is obtained Turning in Valve clearance is decreased Turning out Valve clearance is increased Valve adjusting tool YM 8035 90890 01311 Hold the adjuster to prev...

Page 55: ... not start the engine when cleaning the exhaust system 1 Remove Bolt tailpipe 1 2 Remove Tailpipe 2 Pull the tailpipe out of the muffler 3 Clean Spark arrester Use a wire brush to remove any carbon deposits from the spark arrester portion of the muffler body 3 inner surface Tap the tailpipe lightly and remove the carbon deposits from the outside por tion a of the tailpipe 4 Install Tailpipe Insert...

Page 56: ...ree play Adjustment steps Loosen the locknuts 1 Turn the adjusters 2 in or out until the specified free play is obtained Turning in Free play is increased Turning out Free play is decreased Tighten the locknuts CAUTION Make sure that there is no brake drag after adjusting the front brake lever free play Free play 10 20 mm 0 39 0 79 in Adjustment steps Turn the adjuster 1 in or out until the specif...

Page 57: ... this tight chain position Drive chain slack 40 53 mm 1 6 2 1 in 3 Adjust Drive chain slack Drive chain slack adjustment steps Loosen the wheel axle nut 1 Adjust chain slack by turning the adjusters 2 To tighten Turn adjuster 2 clockwise To loosen Turn adjuster 2 counter clockwise and push wheel forward Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a...

Page 58: ... front fork Unsmooth action oil leakage Repair or replace EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect Swingarm smooth action Abnormal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1 Elevate the rear wheel by placing the suitable stand under the engine 2 Remove Rear shock absorber Refer t...

Page 59: ...rber Refer to SWINGARM section in the CHAPTER 5 EC36Q000 TIRE PRESSURE CHECK 1 Measure Tire pressure Out of specification Adjust NOTE Check the tire while it is cold Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low A tilted tire valve stem indicates that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is...

Page 60: ...n After a practice or a race check spokes for looseness T R 2 Nm 0 2 m kg 1 4 ft lb EC36T000 WHEEL INSPECTION 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace 2 Inspect Bearing free play Exist play Replace STEERING HEAD INSPECTION AND ADJUSTMENT 1 Elevate the front wheel by placing a suit able stand under the engine 2 Check Steering shaft Grasp the bottom of the forks a...

Page 61: ...ut wrench 5 and turn the steering right and left a few times NOTE Set the torque wrench to the ring nut wrench so that they form a right angle Ring nut wrench YM 33975 90890 01403 T R Ring nut initial tightening 38 Nm 3 8 m kg 27 ft lb Loosen the ring nut one turn Retighten the ring nut using the ring nut wrench WARNING Avoid over tightening T R Ring nut final tightening 1 Nm 0 1 m kg 0 7 ft lb Ch...

Page 62: ...N Install the handlebar holder with its groove a facing outward and tighten the bolts so that the gaps b are equal T R Steering stem bolt 40 Nm 4 0 m kg 2 9 ft lb Front fork cap bolt 40 Nm 4 0 m kg 2 9 ft lb Handlebar upper holder 13 Nm 1 3 m kg 9 4 ft lb a b b ...

Page 63: ... lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Brake cable end Å Use Yamaha cable lube or equivalent on these areas ı Use SAE 10W 30 motor oil or suitable chain lubricants Ç Lubricate the following areas with high quality lightweight lithium soap base grease A A A A A B C C 7 8 ...

Page 64: ...eds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4 Clean the plug with a spark plug cleaner if necessary Spark plug gap 0 6 0 7 mm 0 02 0 03 in Standard spark plug CR6HSA NGK U20FSR U DENSO 5 Tighten Spark plug NOTE Before installing a spark plug clean...

Page 65: ...ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank 1 Clamp air filter joint 1 Loosen the screw air filter joint 2 Carburetor heater lead 1 3 Air vent hose 1 4 Fuel hose 1 5 Bolt 2 6 Carburetor assembly 1 7 O ring 1 8 Spacer 1 9 Carburetor top 1 10 Starter plunger assembly 1 1 CARBURETOR 4 ...

Page 66: ...r disassembly Extent of removal Order Part name Q ty Remarks CARBURETOR DISASSEMBLY 1 Throttle valve 1 2 Throttle cable 1 3 Spring 1 4 Gasket 1 5 Carburetor top cover 1 6 Jet needle stopper 1 7 Jet needle assembly 1 8 Starter plunger assembly 1 9 Starter cable 1 0 Float chamber 1 1 ...

Page 67: ...OR Extent of removal Order Part name Q ty Remarks A Float pin 1 B Float 1 C Needle valve 1 D Main jet 1 E Pilot jet 1 F Needle jet 1 G Throttle stop screw assembly 1 H Pilot air screw assembly 1 I Carburetor heater 1 1 ...

Page 68: ...n jet 1 Pilot jet 2 Needle jet 3 Damage Replace Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire Needle valve 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean EC464301 Throttle valve 1 Check Free movement Stick Repair or replace NOTE Insert the throttle valve 1 into the carburetor body ...

Page 69: ... the measurement when the needle valve aligns with the float arm If the carburetor is level the weight of the float will push in the needle valve result ing in an incorrect measurement Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE The float arm should be resting on the nee dle valve but not compressing the needle valve If th...

Page 70: ...crew until it is lightly seated Back out it by the specified number of turns Pilot air screw 1 3 4 turns out 2 Install Throttle valve 1 Starter plunger 2 NOTE Align the slit a of the throttle valve with the tab b of the carburetor top FUEL LEVEL ADJUSTMENT WARNING Gasoline fuel and its vapors are highly flammable and explosive Keep away from sparks cigarettes flames or other sources of ignition ...

Page 71: ...4 7 ENG CARBURETOR 1 Measure Fuel level a Use a fuel level gauge 1 Out of specification Adjust Fuel level gauge YM 1312 A 90890 01312 Fuel level 2 3 mm 0 08 0 12 in below the float chamber line ...

Page 72: ...nd rear fender Exhaust pipe Carburetor Refer to CARBURETOR section Air filter case and starter lever 1 Plug cap spark plug 1 1 2 Crankshaft end cover O ring 1 1 3 Timing plug O ring 1 1 4 Camshaft sprocket cover O ring 1 1 5 Tappet cover intake O ring 1 1 6 Tappet cover exhaust O ring 1 1 7 Camshaft sprocket bolt washer 1 1 Refer to REMOVAL POINTS 8 Timing chain tensioner 1 9 Gasket 1 1 ...

Page 73: ...4 9 ENG CYLINDER HEAD Extent of removal Order Part name Q ty Remarks 10 Camshaft sprocket 1 Refer to REMOVAL POINTS 11 Timing chain 1 12 Cylinder head 1 13 Gasket 1 14 Dowel pin 2 1 ...

Page 74: ...Center T D C NOTE In order to be sure that the piston is at Top Dead Center the match mark c on the camshaft sprocket must align with the sta tionary pointer d on the cylinder head as shown in the illustration If there is no valve clearance rotate the crankshaft counterclockwise one turn 2 Loosen Camshaft sprocket bolt 1 3 Remove Timing chain tensioner Camshaft sprocket 2 NOTE Fasten a safety wire...

Page 75: ...tration Tighten the bolts and nuts in two stages T R 22 Nm 2 2 m kg 16 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install Camshaft sprocket 1 Installation steps Turn the crankshaft counterclockwise until the I mark a on the rotor is aligned with the stationary pointer b on the crankcase cover Align the I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head Fit the timing ch...

Page 76: ...ark Align with the crankcase stationary pointer Valve clearance Out of specification Adjust Refer to the VALVE CLEARANCE ADJUSTMENT section in CHAPTER 3 Installation steps Remove the tensioner cap bolt 1 and spring 2 Release the timing chain tensioner one way cam 3 and push the tensioner rod 4 all the way in Install the tensioner with a new gasket 5 onto the cylinder T R Timing chain tensioner bol...

Page 77: ...e Q ty Remarks CAMSHAFT AND ROCKER ARMS Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Rocker arm shaft intake 1 Use special tool 2 Rocker arm shaft exhaust 1 Refer to REMOVAL POINTS 3 Rocker arm 2 4 Camshaft bearing retainer 1 5 Camshaft 1 6 Valve clearance adjust screw locknut 2 7 Valve clearance adjust screw 2 1 2 ...

Page 78: ...lide hammer bolt 90890 01085 Weight 90890 01084 INSPECTION Camshaft 1 Measure Cam lobes length a and b Out of specification Replace Cam lobes length limit Intake a 25 398 mm 0 9999 in b 21 004 mm 0 8269 in Exhaust a 25 256 mm 0 9943 in b 21 017 mm 0 8274 in ASSEMBLY AND INSTALLATION 1 Apply Molybdenum disulfide oil onto the camshaft cam lobe Engine oil onto the camshaft bearing 2 Install Camshaft ...

Page 79: ...4 15 ENG CAMSHAFT AND ROCKER ARMS 3 Apply Molybdenum disulfide oil onto the rocker arm and rocker arm shaft 4 Install Rocker arm 1 Rocker arm shaft 2 ...

Page 80: ... ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section Rocker arm and camshaft Refer to CAMSHAFT AND ROCKER ARMS section 1 Valve cotter 4 Use special tool Refer to REMOVAL POINTS 2 Spring retainer 2 3 Valve spring 2 4 Intake valve 1 5 Exhaust valve 1 6 Valve stem seal 2 1 ...

Page 81: ...ssor YM 4019 90890 04019 INSPECTION Valve 1 Measure Stem to guide clearance Out of specification Replace the valve guide Stem to guide clearance valve guide inside diameter a valve stem diameter b Clearance stem to guide Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 003 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 004 in 2 Measure Runout valve stem Out of specification Repla...

Page 82: ...th a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps Apply Mechanic s blueing dye Dykem b to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern Measure the valv...

Page 83: ...alve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping compound to the valve face and repeat the above steps NOTE After every lapping operation be sure to clean off all of the compound from the valve face and valve seat Apply Mechanic s blueing dye Dyke...

Page 84: ...o the embossed mark as follows Intake G Exhaust L Install the valve springs with the larger pitch a facing upwards b Smaller pitch New 3 Install Valve cotters NOTE While compressing the valve spring with a valve spring compressor and attachment 1 install the valve cotters Valve spring compressor YM 4019 90890 04019 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a ...

Page 85: ...rks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Timing chain guide exhaust 1 2 Cylinder 1 3 Dowel pin 2 4 Gasket 1 5 Piston pin clip 2 Use special tool Refer to REMOVE POINTS 6 Piston pin 1 7 Piston 1 8 Piston ring top 1 Refer to REMOVAL POINTS 9 Piston ring 2nd 1 10 Side rail spacer 2 1 1 2 ...

Page 86: ...e use the piston pin puller set 4 Piston pin puller set YU 1304 90890 01304 Piston ring 1 Remove Piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration INSPECTION Cylinder and piston 1 Inspect Cylinder and piston walls Vertical scratches Replace cylinder and piston 2 Measure Piston to cylinder clearan...

Page 87: ...ure the piston skirt diameter P with a micrometer a 4 mm 0 16 in from the piston bottom edge Piston size P Standard 46 960 46 975 mm 1 8488 1 8494 in If out of specification replace the piston and piston rings as a set 3rd step Calculate the piston to cylinder clearance with following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 025 0 ...

Page 88: ...n crown so that the ring will be at a right angle to the cylinder bore a 5 mm 0 20 in 3 Measure Ring end gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of the oil control ring If the oil control ring rails show excessive gap replace all three rings Side clearance Standard Limit Top ring 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring 0 020 0 0...

Page 89: ...ngs so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil Measurement steps Measure the piston pin outside diameter a If out of specification replace the piston pin Outside diameter piston pin 12 996 13 000 mm 0 5117 0 5118 in Limit 12 976 mm 0 5109 in Measure the piston inside diameter b If out of spe...

Page 90: ...ints to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase 4 Lubricate Piston Piston rings Cylinder NOTE Apply a liberal coating of engine oil New Cylinder 1 Install Dowel pins Gasket Cylinder 1 NOTE Install the cylinder with one hand while com pressing the piston rings with the ot...

Page 91: ...der Part name Q ty Remarks CRANKCASE COVER LEFT AND RIGHT REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 1 Shift pedal 1 2 Drive sprocket cover 1 3 Crankcase cover left 1 4 Gasket 1 5 Dowel pin 2 6 Clutch adjusting screw 1 7 Kick crank 1 8 Crankcase cover right 1 9 Gasket 1 10 Dowel pin 2 1 2 ...

Page 92: ...h removal Extent of removal Order Part name Q ty Remarks CLUTCH REMOVAL 1 Bolt clutch spring 4 4 2 Pressure plate 1 3 Washer 1 4 Push rod 1 1 5 Friction plate 5 6 Clutch plate 4 7 Push rod 2 1 8 Clutch boss nut 1 Use special tool 9 Lock washer 1 Refer to REMOVAL POINTS 10 Clutch boss 1 11 Washer 1 12 Clutch housing 1 1 2 3 ...

Page 93: ...ame Q ty Remarks 13 Spacer 1 14 Spacer 1 15 Primary clutch nut 1 Use special tool Refer to REMOVAL POINTS 16 Washer 1 17 Spacer 1 18 Primary clutch housing 1 19 Primary clutch boss 1 20 Clutch carrier 1 21 One way clutch assembly 1 22 Washer 1 3 2 ...

Page 94: ... Clutch holding tool YM 91042 90890 04086 Å ı Primary clutch 1 Remove Primary clutch nut 1 NOTE Loosen the nut while holding the magnet rotor with the sheave holder 2 INSPECTION EC484500 Friction plate 1 Measure Friction plate thickness Out of specification Replace friction plate as a set Measure at all four points Sheave holder YS 1880 A 90890 01701 Friction plate thickness Standard Limit 2 7 2 9...

Page 95: ...asure Push rod 2 bend Out of specification Replace Warp limit 0 2 mm 0 008 in Clutch spring free length Standard Limit 26 2 mm 1 03 in 24 2 mm 0 95 in Bending limit 0 5 mm 0 02 in Primary clutch 1 Measure Primary clutch housing inside diameter Out of specification Replace Primary clutch housing inside diameter 105 mm 4 13 in Limit 106 mm 4 17 in 2 Measure Clutch shoe groove depth a Out of specific...

Page 96: ... tool 3 to hold the clutch boss Å For USA and CDN ı Except for USA and CDN 2 Bend Lock washer tab Sheave holder YS 1880 A 90890 01701 Clutch holding tool YM 91042 90890 04086 T R 50 Nm 5 0 m kg 36 ft lb New T R 70 Nm 7 0 m kg 50 ft lb Å ı Clutch release adjustment 1 Adjust Clutch release Adjustment steps Loosen the locknut 1 Turn in the adjuster 2 until it is lightly seated Turn out by 1 8 turn Ti...

Page 97: ... name Q ty Remarks KICK AXLE REMOVAL AND DISASSEMBLY Preparation for removal Crankcase cover right Refer to CLUTCH section 1 Kick axle assembly 1 2 Circlip 2 3 Spring cover 1 4 Torsion spring 1 5 Spring guide 1 6 Circlip 1 7 Ratchet wheel 1 8 Clip 1 9 Circlip 1 10 Washer wave washer 1 1 11 Kick gear 1 12 Kick axle 1 1 2 ...

Page 98: ...SHAFT REMOVAL Preparation for removal Clutch housing and clutch carrier Refer to CLUTCH section 1 Shift fork guide bar 1 2 Shift arm 3 1 3 Plate washer 1 4 Compression spring 1 5 Shift guide 1 6 Ball holder 1 7 Guide 1 8 Dowel pin 1 9 Plate washer 1 10 Thrust bearing 1 11 Circlip 1 12 Shift lever assembly 1 13 Shift shaft 1 1 ...

Page 99: ...4 35 ENG SHIFT SHAFT Extent of removal Order Part name Q ty Remarks 14 Stopper lever 1 15 Torsion spring 1 16 Circlip 1 17 Plate washer 1 18 Torsion spring 1 19 Shift lever 1 1 ...

Page 100: ...Q ty Remarks OIL PUMP REMOVAL AND DIS ASSEMBLY Preparation for removal Clutch housing and clutch carrier Refer to CLUTCH section Shift shaft Refer to SHIFT SHAFT section 1 Rotary filter 1 2 Oil pump assembly 1 3 Gasket 1 4 Oil pump drive gear 1 5 Oil strainer 1 6 Circlip 1 7 Oil pump driven gear 1 8 Spring washer 1 9 Circlip 1 10 Washer 1 1 2 3 ...

Page 101: ...4 37 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 11 Oil pump cover 1 12 Dowel pin 2 13 Oil pump drive shaft 1 14 Pin 1 15 Inner rotor 1 16 Outer rotor 1 17 Rotor housing 1 3 ...

Page 102: ...ace the oil pump assembly Tip clearance a 0 15 mm 0 0059 in Limit 0 2 mm 0 0079 in Side clearance b 0 13 0 18 mm 0 0051 0 0071 in Limit 0 23 mm 0 0091 in Rotor housing and rotor clear ance c 0 06 0 10 mm 0 0024 0 0039 in Limit 0 15 mm 0 006 in Rotary filter and oil strainer 1 Inspect Rotary filter 1 Oil strainer 2 Damage Replace 3 Upper side 4 Lower side ASSEMBLY AND INSTALLATION Rotary filter 1 I...

Page 103: ...val Extent of removal Order Part name Q ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank Crankcase cover left Refer to CLUTCH section 1 CDI magneto coupler 1 2 Pickup coil stator assembly 1 3 Rotor nut 1 Use special tool Refer to REMOVAL POINTS 4 Rotor 1 5 Woodruff key 1 1 2 ...

Page 104: ...01701 2 Remove Rotor 1 Woodruff key NOTE Use the flywheel puller 2 Center the flywheel puller over the rotor Make sure after installing the holding bolts that the clearance between the flywheel puller and the rotor is the same everywhere If necessary one holding bolt may be turned out slightly to adjust the flywheel puller s position CAUTION Cover the crankshaft end with the box wrench for protect...

Page 105: ...st pipe Air filter case Carburetor Refer to CARBURETOR section Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Engine guard and drive sprocket Engine assembly From the chassis Cylinder head Refer to CYLINDER HEAD section Cylinder and piston Refer to CYLINDER AND PISTON sec tion Clutch housing and clutch carrier Refer to CLUTCH section Kick axle assembly Refer to KICK ...

Page 106: ...haft removal Extent of removal Order Part name Q ty Remarks Shift shaft Refer to SHIFT SHAFT section Oil pump and oil strainer Refer to OIL PUMP section Rotor Refer to CDI MAGNETO section 1 Timing chain guide intake 1 2 Timing chain 1 3 Crankcase right 1 4 Dowel pin 2 5 Crankshaft 1 6 Crankcase left 1 1 2 3 ...

Page 107: ...t limit 0 03 mm 0 0012 in Side clearance 0 10 0 40 mm 0 0039 0 0157 in Radial clearance 0 010 0 025 mm 0 0004 0 0010 in 0 05 mm 0 002 in Crack width 42 95 43 00 mm 1 691 1 693 in ASSEMBLY AND INSTALLATION Crankcase 1 Apply Sealant On the crankcase left NOTE Clean the contacting surface of crankcase left and right before applying the sealant DO NOT ALLOW any sealant to come in contact with the oil ...

Page 108: ...xle disassembly Extent of removal Order Part name Q ty Remarks SHIFT FORK SHIFT CAM TRANSMISSION REMOVAL Preparation for removal Engine assembly Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Guide bar 1 2 Shift cam 1 Refer to REMOVAL POINTS 3 Shift fork 2 R 1 4 Shift fork 1 L 1 5 Drive axle assembly 1 6 Main axle assembly 1 7 2nd pinion gear 1 8 Circlip 1 9 Washer 1 1 2 ...

Page 109: ...RANSMISSION Extent of removal Order Part name Q ty Remarks 10 3th pinion gear 1 11 Main axle 1 12 Circlip 1 13 Washer 1 14 Collar 1 15 1st wheel gear 1 16 3rd wheel gear 1 17 Circlip 1 18 Washer 1 19 2nd wheel gear 1 20 Drive axle 1 2 3 ...

Page 110: ...fully Note the posi tion of each part Pay particular attention to the location and direction of shift forks ASSEMBLY AND INSTALLATION Transmission shift cam shift fork 1 Install Main axle assembly 1 Drive axle assembly 2 2 Install Shift fork 1 L 1 Shift fork 2 R 2 Shift cam 3 Guide bar 4 NOTE The embossed marks on the shift forks should face towards the right side of the engine and be in the follo...

Page 111: ...t name Q ty Remarks FRONT WHEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine 1 Bolt brake cable holder 1 Only loosening 2 Brake cable 1 Disconnect at the lever side 3 Wheel axle nut 1 4 Front wheel axle 1 5 Front wheel 1 6 Collar set 1 7 Brake shoe plate assembly 1 8 Oil...

Page 112: ...5 2 CHAS Extent of removal Order Part name Q ty Remarks 10 Brake shoe 2 11 Brake camshaft lever 1 12 Brake camshaft 1 3 FRONT WHEEL AND REAR WHEEL ...

Page 113: ...t name Q ty Remarks REAR WHEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine 1 Brake rod 1 2 Cotter pin 1 3 Nut tension bar 1 4 Bolt tension bar 1 5 Wheel axle nut 1 6 Rear wheel axle 1 7 Drive chain puller 2 8 Rear wheel 1 9 Collar right 1 10 Brake shoe plate assembly 1 ...

Page 114: ...WHEEL AND REAR WHEEL Extent of removal Order Part name Q ty Remarks 11 Collar left 1 12 Wheel drive hub assembly 1 13 Bearing 2 Refer to REMOVAL POINTS 14 Brake shoe 2 15 Brake camshaft lever 1 16 Brake camshaft 1 3 2 ...

Page 115: ...heel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in Brake lining 1 Inspect Brake shoe lining surface Glazed areas Polish Use coarse sand paper NOTE After polishing wipe the polished particles with a cloth 2 Measure Brake shoe lining thickness Out of specification Replace NOTE Replace the brake shoes and springs as a set if either is worn to the limit Brake shoe lining thickness a St...

Page 116: ...ne securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Handlebar Refer to HANDLEBAR section Front fender 1 Brake cable holder 1 2 Cap bolt 1 3 Adjuster 1 Only loosening 4 Pinch bolt under bracket 1 Only loosening 5 Front fork 1 1 ...

Page 117: ...oval Extent of removal Order Part name Q ty Remarks FRONT FORK DISASSEMBLY Preparation for disas sembly Drain the fork oil 1 Adjuster 1 2 Fork spring 1 3 Dust cover 1 4 Stopper ring 1 5 Bolt damper rod 1 Use special tool Refer to REMOVAL POINTS 6 Inner tube 1 7 Damper rod 1 8 Oil seal 1 9 Outer tube 1 1 2 ...

Page 118: ...55000 ASSEMBLY AND INSTALLATION Front fork assembly 1 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver weight 2 and fork seal driver attachment 3 2 Fill Fork oil 3 After filling up slowly pump the fork up and down to distribute the fork oil Fork seal driver weight YM 33963 90890 01184 Fork seal driver attachment 90890 01186 Oil quantity 64 cm3 2 26 Imp oz 2 16 U...

Page 119: ...marks HANDLEBAR REMOVAL 1 ENGINE STOP switch 1 2 Brake lever cable 1 Disconnect at the lever side 3 Brake lever 1 4 Grip cap lower 1 5 Grip cap upper 1 6 Throttle cable 1 Disconnect at the throttle side 7 Grip right 1 8 Tube guide 1 9 Grip left 1 10 Handlebar holder upper 2 11 Handlebar 1 12 Handlebar holder lower 2 1 ...

Page 120: ...ks STEERING REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Front fork Refer to FRONT FORK section 1 Steering stem bolt 1 2 Handle crown 1 3 Ring nut 1 Use special tool Refer to STEERING HEAD INSPEC TION AND ADJUSTMENT section in the CHAPTER 3 4 Ball race cover 1 5 Under br...

Page 121: ...achine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Rear fender Drive chain 1 Cotter pin 2 2 Pin 2 3 Rear shock absorber 1 4 Pivot shaft 1 Hold the swingarm 5 Swing arm 1 6 Drive chain guide 1 7 Drive chain guard 1 8 Drive chain support 1 1 2 ...

Page 122: ...5 12 CHAS SWINGARM Extent of removal Order Part name Q ty Remarks 9 Cotter pin 1 10 Nut tension bar 1 11 Bolt tension bar 1 12 Tension bar 1 1 ...

Page 123: ... 5 ENGINE STOP switch 6 Thermo switch 7 Carburetor heater 8 Rectifier regulator COLOR CODE B Black Br Brown G Green O Orange R Red W White EC612000 WIRING DIAGRAM G W B R W L W R Br G R W W B Y R O B O B B B Y R Y W Y R B W Y B G G W B W B W Br B R W W W Y O O B B W L Y R R W B B B W R Y R OFF RUN B Y R B B Y Y 1 2 3 4 5 6 7 8 B R Black Red B W Black White G W Green White W L White Blue W R White ...

Page 124: ... Fuel tank Use the following special tools in this inspection Spark gap test Clean or replace spark plug Check entire ignition system for connection Repair or replace Check ENGINE STOP switch Replace Check ignition coil Primary coil Replace Secondary coil Replace Check CDI magneto Pickup coil Replace Source coil Replace Replace CDI unit Dynamic spark tester YM 34487 Ignition checker 90890 06754 Po...

Page 125: ...rt engine and increase spark gap until misfire occurs for USA and CDN only Minimum spark gap 6 0 mm 0 24 in Å ı EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace ENGINE STOP SWITCH INSPECTION 1 Inspect ENGINE STOP switch continuity No continuous while being pushed Replace Continuous while being pushed Replace...

Page 126: ...y coil resistance Out of specification Replace NOTE When inspecting the secondary coil resis tance remove the spark plug cap CDI MAGNETO INSPECTION 1 Inspect Pickup coil resistance Out of specification Replace Tester lead Spark plug lead 1 Tester lead Orange lead 2 Secondary coil resistance Tester selector position 6 3 9 5 kΩ at 20 C 68 F kΩ 1 Tester lead Red lead 1 Tester lead White lead 2 Pickup...

Page 127: ...C IGNITION SYSTEM 2 Inspect Source coil resistance Out of specification Replace Tester lead Brown lead 1 Tester lead Green lead 2 Source coil resistance Tester selector position 688 1 032 Ω at 20 C 68 F Ω 100 ...

Page 128: ...ove the following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection Check entire carburetor heating system for connec tion Repair or replace Check thermo switch Replace Check carburetor heater Replace Check CDI magneto Source coil Replace Replace rectifier regulator Pocket tester YU 3112 C 90890 03112 OK OK OK No good No good No good No good OK ...

Page 129: ...TION 1 Inspect Thermo switch operation Faulty operation Replace Inspection steps Remove the thermo switch Connect the pocket tester to the thermo switch coupler as shown Tester lead Black 1 Tester lead Black 2 Immerse the thermo switch in a container filled with water 3 Place a thermometer 4 in the water Slowly heat the water and then let it cool to the specified temperature as indicated in the ta...

Page 130: ...t steps 1 2 Heating phase Test steps 3 4 Cooling phase WARNING Handle the thermo switch with special care Never subject the thermo switch to strong shocks If the thermo switch is dropped replace it Check the thermo switch operation CARBURETOR HEATER INSPECTION 1 Inspect Carburetor heater resistance Out of specification Replace Tester probe Carburetor heater terminal 1 Tester probe Carburetor heate...

Page 131: ... AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc MAINTENANCE RECORD Copies of work orders and or receipts for parts you purchase and install will be required to docu ment maintenance done in accordance with the emission warranty The chart below is printed only as a reminder to you that ...

Page 132: ...PRINTED IN JAPAN 2002 04 3 0 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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