Yamaha TZ125M1 Owner'S Service Manual Download Page 1

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4JT-28199-16

LIT-11626-13-42

OWNER’S SERVICE MANUAL

TZ125M1/(M)

Summary of Contents for TZ125M1

Page 1: ...4JT 28199 16 LIT 11626 13 42 OWNER S SERVICE MANUAL TZ125M1 M ...

Page 2: ...amaha Motor Corporation U S A 1st Edition August 1999 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 13 42 EC010000 ...

Page 3: ...ne please contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become outdat ed If you have any questions please consult your Yamaha dealer W PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND U...

Page 4: ...ON This model is sold AS IS WITHOUT ANY WARRANTIES EXPRESSED OR IMPLIED REGARD LESS OF THE INTENDED USE THE PURCHASER OF THIS MACHINE which is intended for competition purposes IS RESPON SIBLE FOR ALL COSTS SERVICE AND OR REPAIR ...

Page 5: ...WEAR PROTECTIVE APPAR EL When operating this machine always wear an approved helmet with gog gles or a face shield Also wear heavy boots gloves and protective cloth ing Always wear proper fitting cloth ing that will not be caught in any of the moving parts or controls of the machine 4 ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER For safety and reliability the machine must be properly maint...

Page 6: ...t fumes are poisonous These fumes contain carbon monox ide which by itself is odorless and colorless Carbon monoxide is a dan gerous gas which can cause uncon sciousness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machine Do not park the machine on a slope or soft ground as it may fall over 9 PROPERLY SECURE THE MACHINE...

Page 7: ...his machine and should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become outdat ed due to improvements made to this model in the future If there is any question you have regarding this manual or your machine please consult your Yamaha dealer Weights of machines without fuel The minimum weights for road race machines are for the class 125 cc...

Page 8: ...ust be taken 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 seven chapters General Information Specifications Regular inspection and adjustments Engine Chassis Electrical and Tuning 2 The table of contents is at the beginning of the manual Look over the general layout of the book...

Page 9: ... job 6 For jobs requiring more information the step by step format supplements 6 are given in addi tion to the exploded diagram and job instruction chart CLUTCH 4 25 ENG EC4A8100 CLUTCH HOUSING AND PUSH LEVER AXLE Extend of removal 1 Clutch housing removal 2 Push lever axle removal Extend of removal Order Part name Q ty Remarks CLUTCH HOUSING AND PUSH LEVER AXLE REMOVAL 1 Nut clutch boss 1 2 Lock ...

Page 10: ...ling fluid Lubricant Tightening Specified value Service limit Resistance Ω Voltage V Electric cur rent A Illustrated symbols to ª in the exploded dia grams indicate grade of lubricant and location of lubrication point Apply transmission oil Apply engine mixing oil Apply molybdenum disulfide oil Apply lightweight lithium soap base grease ª Apply molybdenum disulfide grease Illustrated symbols º to ...

Page 11: ...MEMO ...

Page 12: ...EC090000 INDEX GENERAL INFORMATION GEN INFO 1 TUNING TUN 7 CHASSIS CHAS 5 ELECTRICAL ELEC 6 ENGINE ENG 4 REGULAR INSPECTION AND ADJUSTMENTS INSP ADJ 3 SPECIFICATION SPEC 2 ...

Page 13: ...ON 1 15 STARTING AND BREAK IN 1 16 TORQUE CHECK POINTS 1 19 CLEANING AND STORAGE 1 20 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 GENERAL TORQUE SPECIFICATIONS 2 11 DEFINITION OF UNITS 2 11 CABLE ROUTING DIAGRAM 2 12 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 4 LOCKING WIRE INSTALLATION GU...

Page 14: ...42 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 48 CDI MAGNETO 4 58 ENGINE REMOVAL 4 61 CRANKCASE CRANKSHAFT AND WATER PUMP 4 65 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT BRAKE AND REAR BRAKE 5 9 FRONT FORK 5 25 HANDLEBAR 5 39 STEERING 5 44 SWINGARM 5 51 REAR SHOCK ABSORBER 5 58 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 SOLENOID VALVE SYSTEM 6 6 ...

Page 15: ...N INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever 2 ENGINE STOP button 3 Water temperature gauge 4 Front brake lever 5 Throttle grip 6 Radiator cap 7 Fuel tank cap 8 Valve joint 9 Front fork 0 Radiator Check bolt Transmission oil level Rear brake pedal Steering damper Fuel cock Rear shock absorber Drive chain Shift pedal Starter knob ª CDI magneto 1 ...

Page 16: ...ne EC121001 VEHICLE IDENTIFICATION NUMBER For USA CDN AUS NZ and E The vehicle identification number 1 is stamped on the right of the steering head pipe EC122001 FRAME SERIAL NUMBER Except for USA CDN AUS NZ and E The frame serial number 1 is stamped on the right of the steering head pipe EC123001 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side o...

Page 17: ...OOLS section 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 speed up assembly time and help assure that all parts are cor r...

Page 18: ... 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 numbers facing outward In other words the stamped letters must be on the side exposed to view When installing oil seal s apply a light coating of light weight lithium base grease to the seal lip s Oil the bearings libera...

Page 19: ...that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 6 Connect Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE If there in no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wireharness For a field remedy use a contact revitalizer available on...

Page 20: ...to split the crankcase as well as remove the crankshaft from either case YM 01189 90890 01189 Flywheel puller YM 01189 90890 01189 This tool is used to remove the flywheel magneto YU 01235 90890 01235 Rotor holding tool YU 01235 90890 01235 This tool is used when loosening or tightening the flywheel magneto securing nut YU 03097 90890 01252 Dial gauge and stand YU 03097 90890 01252 YU 01256 Stand ...

Page 21: ...441 90890 01441 This tool is used to compress the fork spring YM 01442 90890 01442 Fork seal driver YM 01442 90890 01442 This tool is used when install the fork oil seal YM 01455 90890 01455 Pivot shaft wrench YM 01455 90890 01455 YM 01476 90890 01476 Pivot shaft wrench adapter YM 01476 90890 01476 These tools are used to loosen or tighten the pivot adjust bolt YU 03112 90890 03112 Yamaha pocket t...

Page 22: ... 05 01 Quick gasket ACC 11001 05 01 90890 85505 90890 85505 YAMAHA Bond No 1215 This sealant Bond is used for crankcase mating surface etc ACC 11001 30 00 Quick gasket ACC 11001 30 00 90890 05143 90890 05143 YAMAHA Bond No 4 This sealant Bond is used for crankcase mating surface etc ...

Page 23: ...the clutch The lever should be pulled rapidly and released slowly for smooth starts EC153000 SHIFT PEDAL The gear ratios of the constant mesh 6 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine EC155001 THROTTLE GRIP The throttle grip 1 is located on the right han dlebar it accelerates or decelerates the engine For acceleration...

Page 24: ...ull the starter knob out to open the circuit for starting When the engine has warmed up push it in to close the circuit EC15V000 TACHOMETER A stepping motor type tachometer is provided for greater accuracy of the tachometer 1 This tachometer features the following Sweeping After the engine is started the tachometer hand sweeps widely once over the tachometer face and then returns to the zero posit...

Page 25: ...ng to the change in the water temperature NOTE Water temperature may be 60 C 140 F when engine is operated in good conditions Cooling water Display Conditions temp 19 C LO is display 66 F 20 119 C Temperature is 68 247 F displayed 120 140 C Temperature 248 284 F flash 141 C Message HI 285 F flash EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel ta...

Page 26: ...wl the carburetor settings will become faulty EC15M001 CATCH TANK Put the tip of the breather hose into the catch tank 1 and frame 2 Take care not to allow the fuel oil and cooling water to spill on the course 3 Radiator breather hose 4 Fuel tank breather hose 5 Transmission oil breather hose NOTE When putting in the fuel tank breather hose its tip having a cut a should be on the frame side EC15N0...

Page 27: ...f the mainstand and rear wheel axle Be sure to install the clip 4 in the end of the stand shaft W Never apply additional force to the main stand Remove this mainstand before starting out EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it W Never apply additional force to the side stand Remove this sidestand before starting out GEN IN...

Page 28: ...S Unleaded fuel only 5 NOTE Except for AUS 1 If knocking or pinging occurs use a differ ent brand of gasoline or higher octane grade 2 If unleaded gasoline is not available then leaded gasoline can be used C CCAUTION Never mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank and the carburetor float bowl of old premi...

Page 29: ...n a well venti lated area If you should swallow some lacquer thinner inhale excess lacquer thinner vapors or allow any lacquer thin ner to get into your eyes contact a doctor immediately NOTE When the machine is not in use for a long time apply a rust inhibitor to the brake disc After riding in the rainy weather wipe the moisture completely off the disc If rust appears on the brake disc carefully ...

Page 30: ...t gear 3 Apply the clutch lever and push the machine 4 After gaining some momentum release the clutch lever 5 As soon as the engine starts quickly apply the clutch lever again and open the throttle grip slightly at the same time so as to sus tain idling of the engine Then shift the transmission into neutral 6 After applying full throttle a few times push the starter knob CHOKE to the original posi...

Page 31: ...ng break in mask part of the radiator core so that the water temperature is 60 65 C 140 149 F 4 Operate the machine under 8 000 r min and run on a course about 10 km 6 miles While making a straight line run open the throttle from time to time taking care not to exceed the revolution limit 5 Go back to the pit to check for looseness leakage and other failures in installation 6 Next operate the mach...

Page 32: ...piston head for burning to see if there is any problem Refer to SETTING section in the CHAPTER 7 11 Run about 10 km 6 miles in a usual man ner Then do the plug chop Check the pis ton head for burning to see if there is any problem EC195001 BREAKING IN AFTER REPLACEMENT After a part is replaced with a new one it is necessary to break it in as in a new machine This is required especially when the fo...

Page 33: ... For link type Assembly of links Link to frame Link to shock absorber Link to swingarm Rear Installation of shock absorber Shock absorber to frame Rear Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of front axle Tightening of axle holder Rear Tightening of rear axle Sprocket damper to sprocket Brake Hydraulic type Front Caliper to front fork Brake ...

Page 34: ...wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated car washers 4 After the majority of the dirt has been hosed off wash all surfaces with warm water and a mild detergent Use an old toothbrush to clean hard to reach places 5 Rinse the machine off immediately ...

Page 35: ...the cylinder walls with oil 3 Remove the drive chain clean it thoroughly with solvent and lubricate it Reinstall the chain or store it in a plastic bag tied to the frame 4 Lubricate all control cables 5 Block the frame up to raise the wheels off the ground 6 Tie a plastic bag over the exhaust pipe out let to prevent moisture from entering 7 If the machine is to be stored in a humid or salt air env...

Page 36: ...placement 124 cm3 4 36 lmp oz 4 19 US oz BoreXStroke 54X54 5 mm 2 126X2 146 in Compression ratio 7 9 1 Starting system Push to start Lubrication system Premix 30 1 Castrol A747 Oil type or grade 2 Cycle Transmission oil Castrol R30 Periodic oil change 0 30 L 0 26 lmp qt 0 32 US qt Total amount 0 33 L 0 29 lmp qt 0 35 US qt Cooling water capacity including all routes 0 85 L 0 75 lmp qt 0 90 US qt F...

Page 37: ...gle 22 6 Trail 85 5 mm 3 37 in Tire Type Tubeless Size front 95 70 R17 Size rear 125 55 R17 Tire pressure front and rear 180 kPa 1 8 kg cm2 26 psi Brake Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber F...

Page 38: ...2 085 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 0020 in Connecting rod big end side clearance D 0 2 0 7 mm 0 008 0 028 in Small end free play F 0 8 1 0 mm 0 031 0 039 in 2 0 mm 0 08 in Clutch Friction plate thickness 2 9 3 1 mm 0 114 0 122 in 2 7 mm 0 106 in Quantity 6 Clutch plate thickness 1 4 1 8 mm 0 055 0 071 in Quantity 5 Warp limit 0 1 mm 0 004 in Clutch spring free length 36 0 mm 1 417...

Page 39: ...85 Power jet P W J 60 Float arm height F H 5 5 7 5 mm 0 22 0 30 in Reed valve Thickness reed valve 1 0 42 mm 0 017 in reed valve 2 0 34 mm 0 013 in Valve stopper height 10 6 11 0 mm 0 417 0 433 in Valve bending limit 0 2 mm 0 008 in Cooling Radiator core size Width 300 mm 11 81 in Height 198 mm 7 80 in Thickness 24 mm 0 94 in Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2 13 5 17 8 psi ...

Page 40: ...8 0 Crankcase M 6 X 1 0 13 11 1 1 8 0 Transmission housing M 6 X 1 0 7 14 1 4 10 Holder crankshaft oil seal M 8 X 1 25 1 16 1 6 11 Blind plug M 8 X 1 25 1 11 1 1 8 0 Oil drain bolt M12 X 1 5 1 23 2 3 17 Oil check bolt M 6 X 1 0 1 9 0 9 6 5 Crankcase cover left M 6 X 1 0 3 11 1 1 8 0 Crankcase cover right M 6 X 1 0 10 11 1 1 8 0 Primary drive gear M10 X 1 25 1 55 5 5 40 Clutch boss M14 X 1 0 1 50 5...

Page 41: ...n Front fork top end 18 mm 0 71 in Rear suspension Shock absorber travel 58 mm 2 28 in Spring free length 150 mm 5 91 in Fitting length 138 mm 5 43 in Min Max 130 150 mm 5 12 5 91 in Spring rate STD K 72 N mm 7 2 kg mm 403 lb in Optional spring No Enclosed gas pressure 1 200 kPa 12 kg cm3 171 psi Swingarm Swingarm free play limit End 1 0 mm 0 04 in Side clearance 0 05 0 35 mm 0 002 0 014 in Wheel ...

Page 42: ...37 1 190 in Brake fluid type DOT 4 Rear disc brake Disc outside dia XThickness 185X4 0 mm 7 28X0 16 in Deflection limit 0 15 mm 0 006 in Pad thickness 4 0 mm 0 16 in 1 0 mm 0 04 in Master cylinder inside dia 12 7 mm 0 500 in Caliper cylinder inside dia 25 4 mm 1 000 in Brake fluid type DOT 4 Brake lever brake pedal Brake pedal position 148 152 mm 5 8 6 0 in Clutch lever free play at lever pivot 2 ...

Page 43: ... disc and wheel hub M 8 X 1 25 3 23 2 3 17 Brake hose front and rear and union bolt M10 X 1 25 2 30 3 0 22 master cylinder Brake hose front and rear and adapter M10 X 1 25 2 14 1 4 10 Brake caliper front and rear and adapter M10 X 1 25 2 26 2 6 19 Front brake caliper and front fork M10 X 1 25 2 35 3 5 25 Brake caliper front and rear and pad pin M10 X 1 25 2 18 1 8 13 Brake caliper front and rear a...

Page 44: ...y arm M10 X 1 25 1 34 3 4 24 Rear shock absorber and locknut preload M46 X 1 5 1 40 4 0 29 Seat height adjuster and locknut M22 X 1 0 1 38 3 8 27 Seat height adjuster and upper bracket M10 X 1 25 1 40 4 0 29 Swingarm and seal guard M 5 X 0 8 4 2 0 2 1 4 Swingarm and brake hose holder M 6 X 1 0 2 8 0 8 5 8 Swingarm and hook M 6 X 1 0 2 10 1 0 7 2 Swingarm and chain guide M 6 X 1 0 2 8 0 8 5 8 Cowli...

Page 45: ...F White Black White Green CDI unit model Manufacturer 4JT 60 DENSO Ignition coil Model Manufacturer TJ0294 DENSO Minimum spark gap 5 mm 0 20 in Primary winding resistance 0 14 0 18 Ω at 20 C 68 F Secondary winding resistance 5 0 7 4 kΩ at 20 C 68 F Prat to be tightened Thread size Q ty Tightening torque Nm mdkg ftdlb Stator M 6 X 1 0 2 7 0 7 5 1 Rotor M12 X 1 25 1 53 5 3 38 Pickup coil M 4 X 0 7 2...

Page 46: ...pecified torque specifications call for clean dry threads Components should be at room temperature A B TORQUE SPECIFICATION Nut Bolt Nm md dkg ftd dlb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 EC230000 DEFINITION OF UNITS Unit Read Definition Measure mm millimeter 10 3 meter Length cm centimeter 10 2 meter Leng...

Page 47: ... brake hose 6 Cable 7 Frame A Do not cut the end of the clamp B Install the clamp with its ends facing backward C Install the clamp with its ends facing upward D Clamp only the wireharness with the clamp ends downward Do not clamp the high tension cord E Cut the clamp so that the protruding portion is less than 5 mm 0 20 in ...

Page 48: ... magneto lead A Install the tachometer assembly with its figures standing upright B Align the tape on the wireharness with the CDI unit mounting boss C Install the CDI magneto lead so that it is not loose D Clamp the coupler with the clamp ends facing backward on the inside of the chassis E Clamp the wireharness at the center of the tape on it ...

Page 49: ...Clamp the water temperature lead at its coupler portion B Position the end of the clamp to the front of the front fork C Be sure the brake hose is not twisted D Do not tighten the clamp too much E Clamp the clutch cable at its adjusting portion F Install the clamp with its ends facing backward ...

Page 50: ...hose holder 2 Reservoir hose 3 Rear brake hose 4 Clamp A Position the reservoir hose with the paint facing upward B Be sure the brake hose is not twisted C Clamp the brake hose with the end of the clamp forward Do not cut the end of the clamp ...

Page 51: ...tem break race 500km 1 000 quired Remarks in km PISTON Inspect and clean Inspect crack Replace PISTON PIN SMALL END BEARING Inspect Replace PISTON RING Inspect Check ring end gap Replace CYLINDER HEAD Inspect and clean Remove carbon Retighten Check O ring CYLINDER Inspect and clean 3 000 km Inspect score marks Replace Inspect wear Retighten CLUTCH Inspect housing friction Inspect and adjust plate ...

Page 52: ...r position and pedal position Check brake disc surface Check brake fluid level and leakage Retighten brake disc bolts caliper bolts and master cylinder bolts Replace pads Replace brake fluid Every one year FRONT FORKS Inspect and adjust Replace oil Suspension oil 01 Replace oil seal REAR SHOCK ABSORBER After rain Inspect and adjust race Lube Lithium base grease Retighten CHAIN GUARD Replace SWINGA...

Page 53: ...in km DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 30 40 mm Replace 1 2 1 6 in DRIVE DRIVEN SPROCKET Inspect and replace Inspect wear DRIVEN SPROCKET DAMPER Inspect and retighten Replace THROTTLE CONTROL CABLE Check routing and connection Yamaha cable lube or SAE Lubricate 10W30 motor oil ...

Page 54: ...he effect of front and rear brake Check brake disc surface P3 13 18 Chain Check chain slack and alignment Check that the chain is lubricated properly P3 19 21 Wheels Check for excessive wear tire pressure and tire wear P3 32 33 Steering Check that the handlebars can be turned smoothly and have no excessive play P3 33 34 Front forks and Check that they operate smoothly and there is no oil rear shoc...

Page 55: ...LOCKING WIRE INSTALLATION GUIDE 3 5 EC340000 LOCKING WIRE INSTALLATION GUIDE INSP ADJ Bolt to bolt Oil drain bolt Oil filler cap and check bolt Bolt Tank rail drain bolt Throttle cable adjuster ...

Page 56: ... injury When the engine has cooled place a thick towel over the radiator cap slowly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it C CCAUTION Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get s...

Page 57: ... Soft water Cooling water capacity 0 85 L 0 75 Imp qt 0 90 US qt 2 C CCAUTION Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water 8 Install Radiator cap Start the engine and warm it up for a sever al minute 9 Check Cooling water level Cooling water level low Add cooling water 10 Install the lower cowl EC355000 RADIATOR CAP INSPECTION 1 In...

Page 58: ...essure Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2 13 5 17 8 psi b 3 Inspect Pressure Impossible to maintain the specified pres sure for 10 seconds Replace EC357002 COOLING SYSTEM INSPECTION 1 Inspect Coolant level 2 Attach Radiator cap tester 1 and adapter 2 Radiator cap tester YU 24460 1 90890 01325 Adapter YU 33984 90890 01352 C 3 Apply the specified pressure Standard pressure 180...

Page 59: ...l contacts either clutch or friction plates EC359001 CLUTCH ADJUSTMENT 1 Check Clutch lever free play a Out of specification Adjust Clutch lever free play a a 2 3 mm 0 08 0 12 in a 2 Adjust Clutch lever free play Clutch lever free play adjustment steps Loosen the locknut 1 Turn the adjuster 2 until free play a is within the specified limits Tighten the locknut INSP ADJ NOTE After adjustment check ...

Page 60: ...it up on upright position by placing the suitable stand 3 Check Transmission oil level Transmission oil level checking steps Remove the oil check bolt 1 Inspect the oil level NOTE Be sure the machine is positioned straight up when inspecting the oil level W Never attempt to remove the checking bolt just after high speed operation The heated oil could spout out causing dan ger Wait until the oil co...

Page 61: ...ntainer under the engine 4 Remove Exhaust pipe Oil drain bolt 1 Oil filler cap 2 Drain the transmission oil 5 Install Copper washerN Oil drain bolt 1 T23 Nm 2 3 mdkg 17 ftdlb Exhaust pipe NOTE After tightening the oil drain bolt to specified torque lock it using a wire 6 Fill Transmission oil Recommended oil Castrol R30 Oil capacity periodic oil change 0 30 L 0 26 Imp qt 0 32 US qt 3 7 Check Oil l...

Page 62: ... previously riveted INSP ADJ Adjusting steps Turn in the pilot air screw until it is lightly seated Turn out the pilot air screw by the factory set number of turns NOTE To optimize the fuel flow at a smaller throttle opening each machine s pilot air screw has been individually set at the factory Before adjusting the pilot air screw turn it in fully and count the number of turns Record this number ...

Page 63: ...ervoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place the other end of the tube into a container e Slowly apply the brake lever or pedal several times f Pull the lever in or push down on the pedal Hold the lever or pedal in position g Loosen the bleed screw and allow the le...

Page 64: ...g the brake system 3 Install Diaphragm Reservoir tank cap EC363010 FRONT BRAKE ADJUSTMENT 1 Adjust Brake lever position a Adjustment steps Turn the adjuster 1 while pushing the brake lever 2 forward until the desired lever position is obtained S Closer Turn the adjuster in b b Farther Turn the adjuster out c c S NOTE Align the mating mark d on the adjuster with the arrow mark e on the brake lever ...

Page 65: ...ation Replace as a set Brake pad thickness a a Standard Limit 5 3 mm 0 21 in 1 0 mm 0 04 in 2 Replace Brake pad Brake pad replacement steps Loosen the pad pin 1 and remove the caliper 2 Remove the cotter pin 3 pad pin 4 pad support 5 and brake pads 6 Connect the transparent hose 7 to the bleed screw 8 and place the suitable con tainer under its end Loosen the bleed screw and push the caliper pisto...

Page 66: ... Refer to BRAKE FLUID LEVEL INSPEC TION section 4 Check Brake lever operation A softy or spongy feeling Bleed brake system Refer to BRAKE SYSTEM AIR BLEED ING section EC366031 REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out of specification Replace as a set Brake pad thickness a a Standard Limit 4 0 mm 0 16 in 1 0 mm 0 04 in 2 Replace Brake pad Brake pad replacement s...

Page 67: ...ighten the bleed screw Bleed screw 6 Nm 0 6 m kg 4 3 ft lb U Install the brake pads 9 pad support 0 pad pin and cotter pin NOTE Always use a new cotter pin Temporarily tighten the pad pin at this point Install the caliper and tighten the pad pin Bolt caliper 23 Nm 2 3 m kg 17 ft lb Pad pin 18 Nm 1 8 m kg 13 ft lb 3 Inspect Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION section 4 Check Br...

Page 68: ...ke fluid to avoid poor brake performance Refill with same type and brand of brake fluid mixing fluids could result in poor brake performance Be sure that water or other contaminants do not enter master cylinder when refill ing Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts EC368011 SPROCKETS INSPECTION 1 Inspect Sprocket teeth a Excessive wear Replace NOTE...

Page 69: ...ION This machine has a drive chain with small rubber O rings 1 1 between the chain plates Steam cleaning high pressure washes certain solvent and kerosene can damage these O rings 3 Inspect O rings 1 drive chain Damage Replace drive chain Rollers 2 Side plates 3 Damage Wear Replace drive chain 4 Measure Drive chain length 10 links a Out of specification Replace Drive chain length 10 links Limit 12...

Page 70: ...N Be sure to install the master link clip to the direction as shown a Turning direction 7 Lubricate Drive chain Drive chain lubricant SAE 30 50W motor oil or chain lubricants suitable for O ring chains EC36A042 DRIVE CHAIN SLACK ADJUSTMENT 1 Hold the machine on upright position by placing the suitable stand 2 Check Drive chain slack a Out of specification Adjust Drive chain slack 30 40 mm 1 2 1 6 ...

Page 71: ...ter clockwise To loosen Turn adjuster 3 3 clockwise S Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of chain puller alignment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear C CCAUTION Too small chain slack will overload the engine and other vital parts keep the slack within the specified l...

Page 72: ...left and right to make the front wheel straight NOTE To make the front wheel straight provide b and c with the same distance as seen along the extension of the line a connecting the rear end of the front wheel 1 and the front end of the rear wheel 2 Figure A shows that the front wheel is turned clockwise b c Figure B shows that the front wheel is straight b c 5 Check Wheel alignment With the front...

Page 73: ...hain pullers as it will provide convenience in your future similar adjustment 7 Install Lower cowl EC36C000 FRONT FORK INSPECTION 1 Inspect Front fork smooth action Operate the front brake and stroke the front fork Unsmooth action oil leakage Repair or replace EC36E002 FRONT FORK TOP END ADJUSTMENT 1 Hold the machine on upright position by placing the suitable stand 2 Remove Cowling Front wheel Fr...

Page 74: ...lts handle crown and under bracket Pinch bolt handle crown 15 Nm 1 5 m kg 11 ft lb Pinch bolt under bracket 20 Nm 2 0 m kg 14 ft lb C CCAUTION Tighten the under bracket to specified torque If torqued too much it may cause the front fork to malfunction Adjust the handlebar position b and steer ing damper stay position c Handlebar position b b 20 mm 0 79 in Steering damper stay position c c Zero mm ...

Page 75: ...pinch bolt steering damper stay toward the front of the chassis 4 Check Steering smooth action Turn the handlebar to make sure no parts are being contacted with others Contact Repair 5 Install Front fender Front wheel Cowling EC36F012 FRONT FORK SPRING PRELOAD ADJUST MENT 1 Adjust Spring preload By turning the adjuster 1 Stiffer a a Increase the spring preload Turn the adjuster 1 1 in Softer b b D...

Page 76: ...0 5 mm 0 02 in changed per click of the adjuster C CCAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged W Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Stiffer a a Increase the rebound damping force Turn the adjuster 1 1 in Softer b b Decrease the rebound damping force Tur...

Page 77: ...tion is zero C CCAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged W Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability INSP ADJ Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the compression damping force Turn the adjuster 1 1 ...

Page 78: ...just when the adjuster is fully turned in this position is zero C CCAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged W Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect Swingarm smooth action Abnormal noise Unsmooth action Gr...

Page 79: ... to turn the adjuster beyond the maximum or minimum length Tighten the lock bolt and locknut Lock bolt 40 Nm 4 0 m kg 29 ft lb Locknut 38 Nm 3 8 m kg 27 ft lb Install the cap 3 Install Fuel tank EC36M051 REAR SHOCK ABSORBER SPRING PRE LOAD ADJUSTMENT 1 Hold the machine on upright position by placing the suitable stand 2 Loosen Locknut 1 NOTE When loosening the locknut use the special tool 2 which ...

Page 80: ... SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust Rebound damping force By turning the adjuster 1 INSP ADJ Stiffer a a Increase the rebound damp ing force Turn the adjuster 1 1 in Softer b b Decrease the rebound damp ing force Turn the adjuster 1 1 out Extent of adjustment Maximum Minimum Fully turned in Fully turned out position position STANDARD POSITION This is the position which is bac...

Page 81: ...ster 1 INSP ADJ Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the compression damping force Turn the adjuster 1 1 out Extent of adjustment Maximum Minimum Fully turned in Fully turned out position position STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Which align the punch m...

Page 82: ...asure Tire pressure Out of specification Adjust Standard tire pressure Front Rear 180 kPa 180 kPa 1 8 kg cm2 26 psi 1 8 kg cm2 26 psi NOTE Check the tire while it is cold 1Air gauge EC36R000 TIRE INSPECTION 1 Inspect Tire surfaces Wear Damage Replace Minimum tire tread depth a a 2 mm 0 08 in a EC36T000 WHEEL INSPECTION 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace IN...

Page 83: ...heck Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth Free play Adjust steering head 4 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut Steering ring nut adjustment steps Remove the cowling Remove the reservoir tank and handle crown Loosen the ring nut 1 using ring nut wrench 2 Ring nut wrench YU 33975...

Page 84: ...eering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings Install the handle crown 5 and reservoir tank 6 Steering shaft nut 7 7 80 Nm 8 0 m kg 58 ft lb Pinch bolt front fork 8 8 15 Nm 1 5 m kg 11 ft lb Bolt reservoir tank 9 9 5 Nm 0 5 m kg 3 6 ft lb º Install the cowling 6 Install Steering damper EC36V002 STEERING DAMPER A...

Page 85: ...heard as the zero position If a click is heard just when the adjuster is fully turned out this position is zero C CCAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged EC36X001 WIRES CABLES 1 Inspect Smooth movement for steering handle By turning the handlebar lock to lock If any caught rubbed Repair Replace INSP ADJ EC36Z000 COWLING INSTAL...

Page 86: ...ever pivots 3 Throttle to handlebar contact 4 Drive chain 5 Throttle cable end 6 Clutch cable end INSP ADJ A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W30 motor oil or suitable chain lubricants C Lubricate the following areas with high qual ity lightweight lithium soap base grease C CCAUTION Wipe off any excess grease and avoid get ting grease on the brake discs A A A B C C ...

Page 87: ...tor 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 Spark plug gap 0 5 0 6 mm 0 020 0 024 in a Standard spark plug R6385 105P 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten Spark plug T19 Nm 1 9 mdkg 13 ftdlb NOTE Before installing a spark plug clean the gas ke...

Page 88: ...on 4 Set the dial gauge to zero at TDC 5 From TDC rotate the rotor clockwise until the dial gauge indicates that the piston is at a specified distance from TDC Ignition timing B T D C 2 3 mm 0 091 in a 6 Check Ignition timing Punch mark a on rotor should be aligned with punch mark b on pick up coil Not aligned Adjust 7 Adjust Ignition timing INSP ADJ Adjustment steps Loosen the screws pick up coil...

Page 89: ...nd of removal Order Part name Q ty Remarks COWLING SEAT AND FUEL TANK REMOVAL Preparation for Turn the fuel cock to OFF removal Disconnect the fuel hose 1 Quick fastener 4 2 Lower cowl 1 3 Clip upper cowl 4 4 Upper cowl 1 5 Screw seat 4 6 Seat 1 7 Fuel tank breather hose 1 Refer to REMOVAL POINTS 8 Clip fuel tank 1 9 Fuel tank 1 1 2 3 T 8 Nm 0 8 mdkg 5 8 ftdlb 4 ...

Page 90: ...POINTS EC4U3100 Fuel tank breather hose 1 Disconnect Fuel tank breather hose 1 NOTE Disconnect the fuel tank breather hose with the valve joint 2 remaining on the fuel tank side so as to prevent fuel from spurting out by the tank inner pressure ENG 4 ...

Page 91: ...ncer removal Extend of removal Order Part name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for Lower cowl Refer to COWLING SEAT AND removal FUEL TANK section 1 Tension spring 2 2 Bolt exhaust pipe 1 3 Exhaust pipe 1 4 Bolt silencer 2 5 Silencer 1 2 1 T 11 Nm 1 1 mdkg 8 0 ftdlb T 21 Nm 2 1 mdkg 15 ftdlb ...

Page 92: ...n Drain the cooling water Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Steering damper Refer to STEERING section in the CHAPTER 5 1 Water temperature gauge lead 1 2 Thermo unit 1 3 Radiator hose 2 1 4 Radiator hose 4 1 5 Radiator breather hose 1 6 Radiator 1 1 T 7 Nm 0 7 mdkg 5 1 ftdlb T 2 Nm 0 2 mdkg 1 4 ftdlb T 2 Nm 0 2 mdkg 1 4 ftdlb T 2 Nm 0 2 mdkg 1 4 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb...

Page 93: ...the cap counter clockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect Radiator core 1 Obstruction Blow out with compressed air through rear of the radiator Bent fin Repair replace ENG EC455000 ASSEMBLY AND INSTALLATION EC4551...

Page 94: ...erature gauge lead 5 NOTE Insert the end of the radiator breather hose into the catch tank Refer to CONTROL FUNCTION section in the CHAPTER 1 Before applying LOCTITE wipe off dirt on the thread of the thermo unit and its recepta cle on the radiator Apply LOCTITE to half of the thermo unit thread portion on the coupler side so as to prevent LOCTITE from protruding into the radiator ENG ...

Page 95: ...on for Cowling and fuel tank Refer to COWLING SEAT AND removal FUEL TANK section 1 Solenoid valve lead 1 Disconnect the solenoid valve lead 2 Clamp carburetor joint 1 Loosen the screw carburetor joint 3 Carburetor 1 4 Carburetor cover 1 5 Carburetor joint 1 6 Reed valve assembly 1 7 Stopper reed valve 2 8 Reed valve 2 2 9 Reed valve 1 2 2 1 T 2 Nm 0 2 mdkg 1 4 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 1 ...

Page 96: ... Order Part name Q ty Remarks CARBURETOR DISASSEMBLY 1 Mixing chamber top 1 2 Throttle valve 1 Refer to REMOVAL POINTS 3 Needle holder 1 4 Jet needle 1 5 Float chamber 1 6 Float pin 1 7 Float 1 8 Needle valve 1 9 Main jet 1 0 Pilot jet 1 Starter plunger 1 Pilot air screw 1 Refer to REMOVAL POINTS Power jet 1 Solenoid valve 1 1 ...

Page 97: ... air screw 1 NOTE To optimize the fuel flow at a smaller throttle opening each machine s pilot air screw has been individually set at the factory Before removing the pilot air screw turn it in fully and count the number of turns Record this number as the factory set number of turns out ENG EC464000 INSPECTION EC464130 Carburetor 1 Inspect Carburetor body Contamination Clean NOTE Use a petroleum ba...

Page 98: ...t 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 and check for free movement ENG EC464410 Jet needle 1 Inspect Jet needle 1 Bends Wear Replace Clip groove Free play exists Wear Replace Clip position Factory set clip position No 3 Groove a EC464511 Float height 1 Measure Float heig...

Page 99: ...e valve but not compressing the needle valve If the float height is not within specification inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float height by bending the float tab b on the float Recheck the float height EC464701 Reed valve 1 Measure Reed valve bending a Out of specification Replace Reed valve bending limit 0 2 mm 0 008 in a Va...

Page 100: ...b NOTE Install the reed valve with the reed valve bending as shown Note the cut a in the lower corner of the reed and stopper plate C CCAUTION Tighten each screw gradually to avoid warping 2 Install Gasket reed valve assembly 1N Reed valve assembly 2 3 Install Carburetor joint 1 Bolt carburetor joint 2 T11 Nm 1 1 mdkg 8 0 ftdlb EC4652A1 Carburetor 1 Install Power jet 1 To carburetor 2 ENG ...

Page 101: ...rburetor in order to remove any foreign particles such as chips etc Apply the engine oil on the solenoid valve thread 3 Install Pilot air screw 1 Note the following installation points Turn in the pilot air screw until it is lightly seated Turn out the pilot air screw by the number of turns recorded before removing µ Pilot air screw Factory set number of turns out 4 Install Starter plunger 1 5 Ins...

Page 102: ...ARBURETOR AND REED VALVE 4 14 6 Install Needle valve 1 Float 2 Float pin 3 NOTE After installing the needle valve to the float install them to the carburetor Check the float for smooth movement 7 Install Float chamber 1 Screw float chamber 2 8 Install Air vent hose 1 Joint 2 ENG ...

Page 103: ...lign the projection a on the ring with the groove b in the needle holder 6 11 Install Mixing chamber top 1 Screw mixing chamber top 2 To carburetor 3 NOTE After installing check the throttle grip for smooth movement EC465310 Carburetor installation 1 Install Carburetor cover 1 Clamp carburetor joint 2 ENG 2 Install Carburetor 1 NOTE Install the projection between the carburetor joint slots ...

Page 104: ...CARBURETOR AND REED VALVE 4 16 3 Tighten Clamp carburetor joint 1 T2 Nm 0 2 mdkg 1 4 ftdlb 4 Connect Solenoid valve lead 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 ENG ...

Page 105: ...aration for Cowling and fuel tank Refer to COWLING SEAT AND removal FUEL TANK section Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Radiator hose 4 Disconnect at cylinder head side Bolt radiator Shift the radiator forward 1 Spark plug 1 2 Bolt cylinder head 6 Loosen each bolt 1 4 turn and remove them after all bolts are loosened 3 Cylinder head 1 4 Nut cylinder 4 5 Cylinder 1 T 20 Nm 2 0...

Page 106: ...ISTON Extend of removal 1 Piston and piston ring removal Extend of removal Order Part name Q ty Remarks PISTON REMOVAL 1 Piston pin clip 2 2 Piston pin 1 3 Piston 1 Refer to REMOVAL POINTS 4 Small end bearing 1 5 Piston ring 1 T 15 Nm 1 5 mdkg 11 ftdlb 1 ...

Page 107: ...2 Small end bearing 3 NOTE Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and piston pin is still difficult to remove use the piston pin puller 4 Piston pin puller YU 01304 90890 01304 A C CCAUTION Do not use a hammer to drive the piston pin out 3 Remove Piston ring 1 NOTE Take care not to scratch the piston and dam age the piston ring ...

Page 108: ... scraper 1 NOTE Do not use a sharp instrument Avoid scratch ing the aluminum 2 Inspect Cylinder inner surface Score marks Repair or replace Use 400 600 grit wet sandpaper C CCAUTION Do not rebore the cylinder 3 Inspect Travel distance for cylinder 3 000 km 1 800 miles or more Replace ENG EC474313 Piston 1 Inspect Piston crown Damage and crack due to detonation Replace Piston pin hole Crack Replace...

Page 109: ...oove to form an angle of 45 Do the chamfering with force applied to this edge Chamfer until the piston ring moves smoothly C CCAUTION Do not over chamfer ENG 3 Check Piston ring free movement Mechanical stick Repair Install the piston ring 1 to the piston and check for free movement 2 Inspect Travel distance for piston 500 km 300 miles or more Replace EC474402 Piston pin and small end bearing 1 In...

Page 110: ...96 in 3 Check Free play when the piston pin 1 is in place in the piston 2 There should be no noticeable for the play Free play exists Replace piston pin and or piston 4 Install Small end bearing Piston pin Into the small end of connecting rod 5 Check Free play There should be no noticeable free play Free play exists Inspect the connecting rod for wear Replace the pin and or con necting rod as requ...

Page 111: ...mm 0 009 0 015 in 0 023 in ENG 3 Measure Side clearance Use a thickness gauge 1 Out of limit Replace piston and or ring Side clearance Standard Limit 0 02 0 06 mm 0 1 mm 0 0008 0 0024 in 0 004 in NOTE Insert the thickness gauge deep in the piston ring groove Then measure the clearance with both sliding surfaces being flush with each other Check at several points EC474720 Combination of piston and ...

Page 112: ...art ENG EC475000 ASSEMBLY AND INSTALLATION EC475261 Piston ring and piston 1 Install Piston ring 1 NOTE Take care not to scratch the piston or damage the piston ring Install the piston ring with its mark N upward Align the piston ring gap with the pin 2 After installing the piston ring check the smooth movement of it 2 Install Gasket cylinder 1N Small end bearing 2 Dowel pin 3 NOTE Apply the engin...

Page 113: ...not allow the clip open ends to meet the piston pin slot b b EC4753B1 Cylinder head and cylinder 1 Apply Engine oil To piston 1 piston ring 2 and cylinder inner surface ENG 2 Install Cylinder 1 C CCAUTION Make sure the piston ring is properly posi tioned Install the cylinder with one hand while compressing the piston ring with the other hand NOTE After installing check the smooth movement of the p...

Page 114: ...ad 1 Copper washer 2 Bolt cylinder head 3 T11 Nm 1 1 mdkg 8 0 ftdlb NOTE Apply the lithium soap base grease on the thread and contact surface of the bolt cylin der head Tighten the bolts cylinder head in stage using a crisscross pattern 6 Install Spark plug 1 T19 Nm 1 9 mdkg 13 ftdlb Spark plug cap 2 Radiator hose 4 3 T2 Nm 0 2 mdkg 1 4 ftdlb ENG ...

Page 115: ...der Part name Q ty Remarks CLUTCH PLATE AND FRICTION PLATE REMOVAL Preparation for Lower cowl Refer to COWLING SEAT AND removal FUEL TANK section Clutch cable Disconnect at engine side 1 Screw clutch spring 5 2 Clutch spring 5 3 Pressure plate 1 4 Friction plate 6 5 Clutch plate 5 6 Cushion spring 1 T 6 Nm 0 6 mdkg 4 3 ftdlb T 6 Nm 0 6 mdkg 4 3 ftdlb 1 ...

Page 116: ...marks CLUTCH HOUSING AND PUSH LEVER AXLE REMOVAL 1 Nut clutch boss 1 2 Lock washer 1 Use special tool 3 Clutch boss 1 Refer to REMOVAL POINTS 4 Spacer 2 1 5 O ring small 1 6 Clutch housing 1 7 O ring large 1 8 Bearing 1 9 Spacer 1 1 10 Ball 1 11 Push rod 1 12 Bolt seat plate 1 13 Seat plate 1 14 Push lever axle 1 T 50 Nm 5 0 mdkg 36 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb 2 1 ...

Page 117: ...SA and CDN EC4A4000 INSPECTION EC484100 Clutch housing and boss 1 Inspect Clutch housing 1 Cracks Wear Damage Replace Clutch boss 2 Scoring Wear Damage Replace EC4A4100 Clutch housing 1 Check Circumferential play Free play exists Replace Gear teeth a Wear Damage Replace O ring 1 Damage Replace EC484400 Clutch spring 1 Measure Clutch spring free length a Out of specification Replace springs as a se...

Page 118: ...ate 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Warp limit 0 1 mm 0 004 in a EC4A4200 Push lever axle 1 Inspect Push lever axle 1 Wear Damage Replace Torsion spring 2 Broken Damage Replace EC4A4300 Push rod axle 1 Inspect Push rod 1 Ball 2 Wear Damage Bend Replace Bending limit 0 2 mm 0 008 in a NOTE The bending valu...

Page 119: ...ver axle oil seal lip and bearing 2 Install Bolt seat plate 1 T11 Nm 1 1 mdkg 8 0 ftdlb NOTE Fit the seat plate 2 in the groove a of the push lever axle 3 and tighten the bolt seat plate EC4A5221 Clutch 1 Install Spacer 1 1 Bearing 2 NOTE Apply the transmission oil on the spacer 1 and bearing 2 Install O ring 1N To spacer 2 2 NOTE Apply the lithium soap base grease on the O ring ENG ...

Page 120: ...ch housing oil seal lip a 4 Install Clutch housing 1 Clutch boss 2 NOTE Install the clutch housing with the clutch boss pushed on it so that the spacer 2 will not come off 5 Install Lock washer 1N Nut clutch boss 2 T50 Nm 5 0 mdkg 36 ftdlb NOTE Use the clutch holding tool 3 4 to hold the clutch boss Clutch holding tool YM 91042 3 3 90890 04086 4 4 B A For USA and CDN B Except for USA and CDN ENG ...

Page 121: ...th a friction plate and ending with a friction plate Yellow colored friction plates are used for the first and final Install the larger inner diameter friction plate d ø100 mm 3 9 in together with the cush ion spring and place them at second from the innermost If grease or oil sticks to any of the clutch plates friction plates and cushion spring be sure to clean them with solvent or replace them 8...

Page 122: ...11 Check Push lever position Push the push lever 1 forward until it stops With the push lever in this position the projection a of the push lever should be aligned with the mating mark b on the crankcase Not aligned Adjust 12 Adjust Push lever position Push lever position adjustment steps Loosen the locknut 1 Turn the adjuster 2 to align the projection of the push lever with the mating mark on the...

Page 123: ...y Remarks PRIMARY DRIVEN GEAR REMOVAL Preparation for Lower cowl Refer to COWLING SEAT AND removal FUEL TANK section Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Clutch Refer to CLUTCH section Drain the transmission oil Refer to TRANSMISSION OIL REPLACEMENT section in the CHAPTER 3 Rotor Refer to CDI MAGNETO section 1 Crankcase cover right 1 2 Primary driven gear 1 3 Thrust plate 1 T 11...

Page 124: ... ty Remarks PRIMARY DRIVE GEAR AND BALANCER SHAFT REMOVAL 1 Bolt primary drive gear 1 2 Primary drive gear 1 3 Balancer drive gear 1 4 Nut balancer weight gear 1 Refer to REMOVAL POINTS 5 Lock washer 1 6 Balancer weight gear 1 7 Weight 1 8 Crankcase cover left 1 9 Balancer shaft 1 Refer to REMOVAL POINTS T 11 Nm 1 1 mdkg 8 0 ftdlb T 8 Nm 0 8 mdkg 5 8 ftdlb T 50 Nm 5 0 mdkg 36 ftdlb T55 Nm 5 5 mdkg...

Page 125: ...r drive gear 3 and balancer weight gear 4 3 Remove Bolt primary drive gear 1 Primary drive gear 2 Balancer drive gear 3 Nut balancer weight gear 4 Lock washer 5 Balancer weight gear 6 NOTE It may sometimes happens that the primary drive gear and balancer drive gear are fitted too tight as in force fitting In that case use a general gear puller to remove them without too much force on the crankshaf...

Page 126: ...C4D4300 Crankcase cover right 1 Inspect Contacting surface Scratches Replace Crankcase cover right Cracks Damage Replace Oil seal 1 Wear Damage Replace EC4D4400 Balancer shaft and weight 1 Inspect Balancer shaft 1 Bend Wear Damage Replace Weight 2 Damage Replace EC4D5000 ASSEMBLY AND INSTALLATION EC4D5122 Balancer shaft and primary drive gear 1 Install Balancer shaft 1 NOTE When installing the bal...

Page 127: ... in numbered order as shown Tighten the screw using the T30 bit 3 Install Weight 1 NOTE Align the punch mark a on the balancer shaft with the punch mark b on the weight 4 Install Balancer weight gear 1 NOTE Align the punch mark a on the balancer shaft with the hole b of the balancer weight gear 5 Install Balancer drive gear 1 NOTE Align the punch marks a balancer drive gear with b crankshaft and c...

Page 128: ...Place an aluminum plate a between the teeth of the balancer drive gear 2 and balancer weight gear 3 8 Bend the lock washer 1 tab 9 Tighten Bolt primary drive gear 1 T55 Nm 5 5 mdkg 40 ftdlb NOTE Place an aluminum plate a between the teeth of the balancer drive gear 2 and balancer weight gear 3 EC4D5202 Primary driven gear 1 Install Primary driven gear 1 To crankcase cover right 2 NOTE Apply the li...

Page 129: ...ith its chamfered por tion a toward the transmission 3 Install Crankcase cover right 1 NOTE Mesh the primary drive gear 2 with the prima ry driven gear 3 and the oil pump drive gear 4 with the oil pump driven gear 5 by turning the rotor 4 Install Bolt crankcase cover right 1 T11 Nm 1 1 mdkg 8 0 ftdlb NOTE Tighten the bolts in stages using a crisscross pattern ENG ...

Page 130: ...ever removal Extend of removal Order Part name Q ty Remarks SHIFT SHAFT REMOVAL Preparation for Lower cowl Refer to COWLING SEAT AND removal FUEL TANK section Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Clutch Refer to CLUTCH section Drain the transmission oil Refer to TRANSMISSION OIL REPLACEMENT section in the CHAPTER 3 Crankcase cover right Refer to PRIMARY DRIVEN GEAR PRIMARY DRIVE...

Page 131: ...l Extend of removal Order Part name Q ty Remarks OIL PUMP REMOVAL 1 Circlip 1 2 Plain washer 1 3 Dowel pin 1 4 Oil pump driven gear 1 5 Shim 1 6 Oil pump assembly 1 7 Oil pump cover 1 8 Oil pump shaft 1 9 Outer rotor 1 10 Inner rotor 1 11 Strainer 1 1 12 Strainer 2 1 T 4 Nm 0 4 mdkg 2 9 ftdlb T 7 Nm 0 7 mdkg 5 1 ftdlb 2 1 ...

Page 132: ...sion spring 3 Broken Replace EC4E4200 Oil pump 1 Measure Tip clearance Measure the clearance between the inner rotor 1 and outer rotor 2 Out of limit Replace the inner rotor and outer rotor as a set Tip clearance limit 0 15 mm 0 0059 in a 2 Inspect Oil pump driven gear 1 Oil pump shaft 2 Wear Damage Replace EC4E4301 Strainer 1 Clean Strainer 1 1 Strainer 2 2 Use compressed air NOTE Clean the strai...

Page 133: ...ing downward After installing the strainers make sure the strainer 1 and 2 are not protruding from the crankcase surface d EC4E5202 Oil pump 1 Install Outer rotor 1 Inner rotor 2 To oil pump housing 3 NOTE Apply the transmission oil on the inner rotor and outer rotor 2 Install Oil pump shaft 1 To inner rotor 2 NOTE Install the oil pump shaft with its flat portion a placed on the flat portion b of ...

Page 134: ...p assembly 1 NOTE Apply the molybdenum disulfide oil on the oil pump shaft 2 When installing the oil pump assembly turn the oil pump shaft until its key end a is in the recess b of the impeller shaft 3 6 Install Screw oil pump assembly 1 T7 Nm 0 7 mdkg 5 1 ftdlb Shim 2 7 Install Oil pump driven gear 1 Dowel pin 2 Plain washer 3 8 Install Circlip 1N ENG ...

Page 135: ...il on the shift shaft 2 Install Plain washer 1 Shift pedal 2 Bolt shift pedal 3 T22 Nm 2 2 mdkg 16 ftdlb Shift arm 4 Bolt shift arm 5 T14 Nm 1 4 mdkg 10 ftdlb NOTE Make sure that the joint rod distance a is 72 5 74 5 mm 2 85 2 93 in Apply the lithium soap base grease on the bolt shift pedal Install the shift arm so that the shift pedal is highest with the distance b between the shift pedal outer d...

Page 136: ...efer to EXHAUST PIPE AND SILENCER section Clutch Refer to CLUTCH section Drain the transmission oil Refer to TRANSMISSION OIL REPLACEMENT section in the CHAPTER 3 Crankcase cover right Refer to PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER SHAFT section Shift shaft and stopper lever Refer to SHIFT SHAFT AND OIL Oil pump driven gear PUMP section T 8 Nm 0 8 mdkg 5 8 ftdlb T 14 Nm 1 4 mdkg 10 f...

Page 137: ...to REMOVAL POINTS 3 Drive sprocket 1 4 Transmission housing 1 Refer to REMOVAL POINTS 5 Oil delivery pipe 1 6 Guide bar short 1 7 Guide bar long 1 8 Shift fork 1 1 9 Shift fork 2 1 10 Shift fork 3 1 11 Main axle 1 12 Drive axle 1 Refer to REMOVAL POINTS 13 Bearing plate cover 2 14 Shift cam 1 Refer to REMOVAL POINTS T 8 Nm 0 8 mdkg 5 8 ftdlb T 14 Nm 1 4 mdkg 10 ftdlb T 8 Nm 0 8 mdkg 5 8 ftdlb T 60...

Page 138: ...t together with the drive chain EC4H3100 Transmission housing 1 Remove Bolt transmission housing Transmission housing 1 NOTE Remove the transmission housing together with the transmission shift cam and shift fork EC4H3210 Transmission 1 Remove Main axle 1 Drive axle 2 NOTE Remove the main axle together with the drive axle from the transmission housing 3 Remove assembly carefully Note the position ...

Page 139: ...position shown in the figure so that it does not contact the trans mission housing EC4H4000 INSPECTION EC4H4100 Oil delivery pipe 1 Inspect Oil delivery pipe 1 O ring 2 Damage Replace Oil orifice a Clogged Blow EC4H4210 Gears 1 Inspect Matching dog a Gear teeth b Wear Damage Replace 2 Check Gears movement Unsmooth movement Repair or replace ENG ...

Page 140: ... Out of specification Replace Shift fork groove a a Standard Limit 5 05 5 18 mm 5 35 mm 0 199 0 204 in 0 211 in EC4H4600 Bearing 1 Inspect Bearing 1 Rotate inner race with a finger Rough spot Seizure Replace EC4H4701 Shift fork and shift cam 1 Inspect Shift fork 1 Wear Damage Scratches Replace 2 Inspect Shift cam 1 Guide bar 2 Bend Wear Damage Replace ENG ...

Page 141: ...SEMBLY AND INSTALLATION EC4H5100 Shift cam 1 Install Shift cam 1 NOTE Turn the segment 2 to the position shown in the figure so that it does not contact the trans mission housing 2 Install Bearing plate cover 1 Bolt bearing plate cover 2 GT8 Nm 0 8 mdkg 5 8 ftdlb EC4H5221 Transmission 1 Install 6th pinion gear 24 T 1 3rd pinion gear 17 20 T 2 5th pinion gear 21 T 3 2nd pinion gear 19 T 4 To main a...

Page 142: ...4 54 2 Install 2nd wheel gear 31 T 1 5th wheel gear 24 T 2 4th wheel gear 25 T 3 3rd wheel gear 24 T 4 6th wheel gear 26 T 5 1st wheel gear 30 T 6 To drive axle 7 NOTE Apply the molybdenum disulfide oil on the gears inner circumference ENG ...

Page 143: ...in axle and drive axle bearings Install the main axle together with the drive axle into the transmission housing 3 5 Install Shift fork 1 1 Shift fork 2 2 Shift fork 3 3 NOTE Mesh the shift fork 1 with the 5th wheel gear 4 and 3 with the 6th gear 6 on the drive axle Mesh the shift fork 2 with the 3rd 4th pinion gear 5 on the main axle 6 Install Guide bar short 1 Guide bar long 2 NOTE Apply the tra...

Page 144: ...nstalling the oil delivery pipe fit the pro jection a of the oil delivery pipe into the hole b on the crankcase 10 Install Dowel pin 1 Transmission housing 2 NOTE Apply the lithium soap base grease on the crankcase oil seal lip When installing the drive axle into the crankcase pay careful attention to the crankcase oil seal lip 11 Install Bolt transmission housing 1 T14 Nm 1 4 mdkg 10 ftdlb NOTE T...

Page 145: ... 2 NOTE Install the drive sprocket with its stepped por tion a facing the engine Install the drive sprocket together with the drive chain 2 Install Lock washer 1N Nut drive sprocket 2 T60 Nm 6 0 mdkg 43 ftdlb NOTE Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut ENG ...

Page 146: ...ks CDI MAGNETO REMOVAL Preparation for Cowling and fuel tank Refer to COWLING SEAT AND removal FUEL TANK section Disconnect the CDI magneto lead 1 Nut rotor 1 Use special tool 2 Rotor 1 Refer to REMOVAL POINTS 3 Stator 1 4 Woodruff key 1 T 2 Nm 0 2 mdkg 1 4 ftdlb T 53 Nm 5 3 mdkg 38 ftdlb T 7 Nm 0 7 mdkg 5 1 ftdlb 1 4 58 ...

Page 147: ...TE When installing the flywheel puller turn it coun terclockwise EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect Woodruff key 1 Damage Replace EC4L5000 ASSEMBLY AND INSTALLATION EC4L5144 CDI magneto 1 Install Stat...

Page 148: ... When installing the rotor align the keyway c of the rotor with the woodruff key 3 Install Plain washer 1 Nut rotor 2 T53 Nm 5 3 mdkg 38 ftdlb Use the rotor holding tool 3 Rotor holding tool YU 01235 90890 01235 A 4 Adjust Ignition timing Ignition timing B T D C 2 3 mm 0 091 in a Refer to IGNITION TIMING CHECK sec tion in the CHAPTER 3 5 Connect CDI magneto lead 1 Refer to CABLE ROUTING DIAGRAM se...

Page 149: ...IPE AND SILENCER section Clutch cable Disconnect at engine side Radiator hose 2 Disconnect at water pump side Radiator hose 4 Disconnect at cylinder head side Shift arm Refer to SHIFT SHAFT AND OIL PUMP section Drive sprocket Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Spark plug cap Disconnect the CDI magneto lead T 30 Nm 3 0 mdkg 22 ftdlb T 8 Nm 0 8 mdkg 5 8 ftdlb T 30 Nm 3 0 mdkg 22 ...

Page 150: ... engine mounting collar 2 Only loosening 2 Nut engine mounting bolt 3 3 Engine mounting adjust bolt 2 4 Engine mounting bolt 3 Refer to REMOVAL POINTS 5 Engine 1 T 30 Nm 3 0 mdkg 22 ftdlb T 8 Nm 0 8 mdkg 5 8 ftdlb T 30 Nm 3 0 mdkg 22 ftdlb T 8 Nm 0 8 mdkg 5 8 ftdlb T11 Nm 1 1 mdkg 8 0 ftdlb T 30 Nm 3 0 mdkg 22 ftdlb 1 ...

Page 151: ...e sure that the couplers hoses and cables are discon nected Remove the engine by lowering it with a jack 3 EC4M5000 ASSEMBLY AND INSTALLATION EC4M5181 Engine installation 1 Install Engine 1 NOTE Install the engine by raising it into the frame with a jack 2 2 Install Engine mounting collar 1 Engine mounting bolt 2 3 Tighten Engine mounting adjust bolt 1 T8 Nm 0 8 mdkg 5 8 ftdlb NOTE Use the adjust ...

Page 152: ...2 ftdlb Nut engine mounting bolt lower 2 T30 Nm 3 0 mdkg 22 ftdlb Nut engine mounting bolt front 3 T30 Nm 3 0 mdkg 22 ftdlb 5 Tighten Pinch bolt engine mounting collar 1 T11 Nm 1 1 mdkg 8 0 ftdlb C CCAUTION After tightening the nuts engine mounting bolts tighten the pinch bolts ENG ...

Page 153: ...EED VALVE section Piston Refer to CYLINDER HEAD CYLIN DER AND PISTON section Push lever axle Refer to CLUTCH section Rotor and stator Refer to CDI MAGNETO section Primary drive gear Refer to PRIMARY DRIVEN GEAR Balancer shaft PRIMARY DRIVE GEAR AND BALANCER SHAFT section Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section T 16 Nm 1 6 mdkg 11 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 23 Nm...

Page 154: ...nd plug 1 Use special tool 4 Crankcase right 1 Refer to REMOVAL POINTS 5 Crankcase left 1 6 Crankshaft 1 Use special tool Refer to REMOVAL POINTS 7 Spacer 1 8 Oil seal crankshaft 2 9 Bearing 2 Refer to REMOVAL POINTS 10 Water pump housing cover 1 11 Circlip 1 12 Impeller shaft 1 13 Oil seal impeller shaft 1 Refer to REMOVAL POINTS T 16 Nm 1 6 mdkg 11 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 23 Nm 2 3 md...

Page 155: ...boss and rear engine mounting boss C CCAUTION Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw realign and start over If the cases do not separate check for a remaining case screw or fitting Do not force EC4N3300...

Page 156: ...Do not use the removed bearing EC4Q3300 Oil seal NOTE It is not necessary to disassembly the water pump unless there is no abnormality such as excessive change in coolant level discol oration of coolant or milky transmission oil 1 Remove Oil seal 1 From crankcase right EC4Q4000 INSPECTION EC4N4101 Crankcase 1 Inspect Contacting surface a Scratches Replace Engine mounting boss b crankcase Cracks Da...

Page 157: ...the dial gauge and a thickness gauge Dial gauge YU 03097 90890 01252 A Standard Limit Runout 0 03 mm 0 05 mm limit 0 0012 in 0 0020 in Small end 0 8 1 0 mm 2 0 mm free play 0 031 0 039 in 0 08 in Side 0 2 0 7 mm clearance 0 008 0 028 in Crank 52 90 52 95 mm width 2 083 2 085 in s EC444200 Impeller shaft 1 Inspect Impeller shaft 1 Bend Wear Damage Replace Fur deposits Clean ENG EC444400 Oil seal 1 ...

Page 158: ...all Impeller shaft 1 NOTE Take care so that the oil seal lip is not dam aged or the spring does not slip off its posi tion When installing the impeller shaft apply the lithium soap base grease on the oil seal lip and impeller shaft And install the shaft while turning it 2 Install Plain washer T 2 0 mm 0 08 in 1 Plain washer T 1 0 mm 0 04 in 2 Circlip 3N To impeller shaft 4 NOTE Install the plain w...

Page 159: ... race parallel EC4Q5310 Oil seal crankshaft 1 Install Oil seal left 1N Oil seal right 2N NOTE Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufacture s marks and numbers facing outward EC4Q5412 Crankshaft 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 Crankshaft installing tool Pot 2 2 YU 90050 90890 01274 Bolt 3 3 YU 90050 90890 01275 Adap...

Page 160: ...thium soap base grease on the oil seal lip C CCAUTION Do not use a hammer to drive in the crank shaft 2 Apply Sealant On the crankcase right 1 Quick gasket ACC 11001 05 01 ACC 11001 30 00 YAMAHA Bond No 1215 90890 85505 YAMAHA Bond No 4 90890 05143 F NOTE Clean the contacting surface of crankcase left and right before applying the sealant C CCAUTION If the engine is started soon after reinstalla t...

Page 161: ...mdkg 8 0 ftdlb NOTE Tighten the crankcase tightening bolts in stage using a crisscross pattern 6 Install Holder 1 Bolt holder 2 GT16 Nm 1 6 mdkg 11 ftdlb Blind plug 3 GT11 Nm 1 1 mdkg 8 0 ftdlb NOTE Install the holder so that it contacts the projec tion a on the crankcase right 7 Install Spacer 1 ENG 8 Remove Sealant Forced out on the crankcase mating sur face 9 Apply Engine oil To the crank pin b...

Page 162: ...RONT WHEEL REMOVAL Preparation for Hold the machine by placing removal the suitable stand 1 Bolt axle holder 2 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Bearing 2 Refer to REMOVAL POINTS 7 Brake disk 1 CHAS T 23 Nm 2 3 mdkg 17 ftdlb T 20 Nm 2 0 mdkg 14 ftdlb T 20 Nm 2 0 mdkg 14 ftdlb T 48 Nm 4 8 mdkg 35 ftdlb 3 1 2 3 5 W Support the machine securely ...

Page 163: ...g removal the suitable stand 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Rear wheel 1 Refer to REMOVAL POINTS 4 Collar 1 5 Clutch hub 1 6 Driven sprocket 1 7 Sprocket damper 4 8 Bearing 2 Refer to REMOVAL POINTS 9 Brake disc 1 CHAS T 63 Nm 6 3 mdkg 45 ftdlb T 23 Nm 2 3 mdkg 17 ftdlb T 2 Nm 0 2 mdkg 1 4 ftdlb T 16 Nm 1 6 mdkg 11 ftdlb T 32 Nm 3 2 mdkg 23 ftdlb 3 1 2 3 W Support the machine secure...

Page 164: ...eral bearing puller 2 EC594000 INSPECTION EC514110 Wheel 1 Measure Wheel runout Out of limit Replace Wheel runout limit Radial 1 0 mm 0 04 in Lateral 0 5 mm 0 02 in b 2 Inspect Bearing Rotate inner race with a finger Rough spot Seizure Replace NOTE Replace the bearings and wheel collar as a set EC514200 Wheel axle 1 Measure Wheel axle bends Out of specification Replace Use the dial gauge 1 Wheel a...

Page 165: ... wheel runout If wheel runout is in good condition replace the brake disc Disc deflection limit Standard Limit Rear 0 15 mm 0 006 in 2 Measure Brake disc thickness Use the micrometer 1 Out of limit Replace Disc wear limit Standard Limit Front 5 0 mm 0 20 in 4 5 mm 0 18 in Rear 4 0 mm 0 16 in 3 5 mm 0 14 in 3 Inspect Brake disc surface Score marks Damege Replace EC524100 Clutch hub 1 Inspect Bearin...

Page 166: ...es the outside diam eter of the race of the bearing Right side of bearing shall be installed first C CCAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Brake disc 1 Bolt brake disc 2 GT23 Nm 2 3 mdkg 17 ftdlb NOTE Tighten the bolts in stage using a crisscross pattern 3 Install Collar 1 4 Install Wheel NOTE Install the brake disc 1 between...

Page 167: ...ighten Bolt axle holder 1 T20 Nm 2 0 mdkg 14 ftdlb EC525191 Rear wheel 1 Install Bearing right 1 Spacer 2 Bearing left 3 NOTE Apply the lithium soap base grease on the bearing when installing Use a socket that matches the outside diam eter of the race of the bearing Right side of bearing shall be installed first C CCAUTION Do not strike the inner race of the bearing Contact should be made only wit...

Page 168: ...ut sprocket damper 2 T32 Nm 3 2 mdkg 23 ftdlb To driven sprocket 3 4 Install Driven sprocket 1 To wheel NOTE Apply the lithium soap base grease on the sprocket damper 5 Install Shim 1 Clutch hub 2 Collar 3 To wheel NOTE Apply the lithium soap base grease on the shim and clutch hub outer circumference 6 Install Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly CHAS ...

Page 169: ...orarily tighten the nut wheel axle at this point 10 Adjust Drive chain slack a Drive chain slack 30 40 mm 1 2 1 6 in a Refer to DRIVE CHAIN SLACK ADJUST MENT section in the CHAPTER 3 11 Tighten Nut wheel axle 1 T63 Nm 6 3 mdkg 45 ftdlb Adjuster 2 T2 Nm 0 2 mdkg 1 4 ftdlb Locknut 3 T16 Nm 1 6 mdkg 11 ftdlb NOTE Tighten the axle nut while pushing down the drive chain After tightening the axle nut ti...

Page 170: ...k 1 8 Reservoir hose 1 9 Master cylinder bracket 1 10 Master cylinder 1 FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extend of removal 1 Brake hose removal 2 Caliper removal 3 Master cylinder removal CHAS T 35 Nm 3 5 mdkg 25 ftdlb T 18 Nm 1 8 mdkg 13 ftdlb T 6 Nm 0 6 mdkg 4 3 ftdlb T 26 Nm 2 6 mdkg 19 ftdlb T 14 Nm 1 4 mdkg 10 ftdlb T 1 Nm 0 1 mdkg 0 7 ftdlb ...

Page 171: ...der 2 2 Adapter 1 3 Union bolt 1 4 Brake hose 1 5 Pad pin 1 Loosen when disassembling the caliper 6 Caliper 1 7 Brake pedal connecting bolt 1 8 Reservoir tank 1 9 Reservoir hose 1 10 Master cylinder 1 W Support the machine securely so there is no danger of it falling over CHAS T 6 Nm 0 6 mdkg 4 3 ftdlb T 18 Nm 1 8 mdkg 13 ftdlb T 12 Nm 1 2 mdkg 8 7 ftdlb T 20 Nm 2 0 mdkg 14 ftdlb T 26 Nm 2 6 mdkg ...

Page 172: ...tend of removal Order Part name Q ty Remarks CALIPER DISASSEMBLY A B 1 Cotter pin 1 1 2 Pad pin 1 1 3 Pad support 1 1 4 Brake pad 2 2 5 Caliper piston 4 2 Refer to REMOVAL POINTS 6 Dust seal 4 2 Refer to REMOVAL POINTS 7 Piston seal 4 2 CHAS T 6 Nm 0 6 mdkg 4 3 ftdlb T 18 Nm 1 8 mdkg 13 ftdlb T 6 Nm 0 6 mdkg 4 3 ftdlb T 18 Nm 1 8 mdkg 13 ftdlb 1 2 A B ...

Page 173: ...ont B Rear Extend of removal 1 Front master cylinder disassembly 2 Rear master cylinder disassembly Extend of removal Order Part name Q ty Remarks MASTER CYLINDER DISASSEMBLY 1 Master cylinder boot 1 2 Circlip 1 3 Master cylinder kit 1 CHAS T 2 Nm 0 2 mdkg 1 4 ftdlb 1 2 A B ...

Page 174: ...k cap 1 NOTE Do not remove the diaphragm A Front B Rear 2 Connect the transparent hose 2 to the bleed screw 1 and place a suitable con tainer under its end A Front B Rear 3 Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal C CCAUTION Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up sp...

Page 175: ... piece of rag into the caliper to lock one caliper Carefully force the piston out of the caliper cylinder with compressed air A Front B Rear EC543411 Piston seal kit 1 Remove Dust seal 1 Piston seal 2 NOTE Remove the piston seals and dust seals by pushing them with a finger C CCAUTION Never attempt to pry out piston seals and dust seals Do not loosen the bolts 3 3 and nuts 4 4 W Replace the piston...

Page 176: ...embly Stains Clean W Use only new brake fluid A Front B Rear 2 Inspect Diaphragm 1 Crack Damage Replace A Front B Rear 3 Inspect Master cylinder piston 1 Master cylinder cup 2 Wear Damage Score marks Replace master cylinder kit A Front B Rear EC534214 Caliper 1 Inspect Caliper cylinder inner surface a Wear Score marks Replace caliper assembly A Front B Rear CHAS ...

Page 177: ... W All internal parts should be cleaned in new brake fluid only Internal parts should be lubricated with brake fluid when installed Replace the piston seals and dust seals whenever a caliper is disassembled EC535113 Caliper piston 1 Clean Caliper Piston seal Dust seal Caliper piston Clean them with brake fluid 2 Install Piston seal 1N Dust seal 2N W Always use new piston seals and dust seals NOTE ...

Page 178: ... to insert A Front B Rear EC535241 Front caliper 1 Install Brake pad 1 Pad support 2 Pad pin 3 Cotter pin 4N NOTE Temporarily tighten the pad pin at this point 2 Install Caliper 1 Bolt caliper 2 T35 Nm 3 5 mdkg 25 ftdlb 3 Tighten Pad pin 3 T18 Nm 1 8 mdkg 13 ftdlb CHAS EC545141 Rear caliper 1 Install Brake pad 1 Pad support 2 Pad pin 3 Cotter pin 4N NOTE Temporarily tighten the pad pin at this poi...

Page 179: ... Clean Master cylinder Master cylinder kit Clean them with brake fluid 2 Install Master cylinder cup primary 1 Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup W After installing cylinder cup should be installed as shown direction Wrong instal lation cause improper brake performance A Front B Rear CHAS ...

Page 180: ...led as shown direction Wrong instal lation cause improper brake performance A Front B Rear 4 Install Master cylinder kit 1 Circlip 2 Master cylinder boot 3 To master cylinder 4 NOTE Apply the brake fluid on the master cylinder kit When installing the circlip use a long nose circlip pliers A Front B Rear EC535421 Front master cylinder 1 Install Reservoir tank 1 Bolt reservoir tank 2 T5 Nm 0 5 mdkg ...

Page 181: ...ark c on the han dlebar 3 Install Brake lever 1 Bolt brake lever 2 T1 Nm 0 1 mdkg 0 7 ftdlb Nut brake lever 3 T6 Nm 0 6 mdkg 4 3 ftdlb NOTE Apply the lithium soap base grease on the bolt When installing the brake lever apply the molybdenum disulfide grease on the contact ing surface of the master cylinder piston EC545232 Rear master cylinder 1 Install Reservoir hose 1 Reservoir tank 2 Bolt reservo...

Page 182: ...asher 1N Brake hose 2 Union bolt 3 T30 Nm 3 0 mdkg 22 ftdlb W Always use new copper washers C CCAUTION Install the brake hose so that it forms an angle a a of 105 to the brake lever 4 4 2 Pass the brake hose through the clamp 1 and hole a of the inner fender 2 3 Install Copper washer 1N Adapter 2 T26 Nm 2 6 mdkg 19 ftdlb Brake hose 3 T14 Nm 1 4 mdkg 10 ftdlb W Always use a new copper washer NOTE W...

Page 183: ...lways use new copper washers C CCAUTION When installing the brake hose to the mas ter cylinder lightly touch the brake pipe a a with the projection b b on the master cylin der 2 Install Copper washer 1N Adapter 2 T26 Nm 2 6 mdkg 19 ftdlb Brake hose 3 T14 Nm 1 4 mdkg 10 ftdlb W Always use a new copper washer NOTE When turning the adapter over the brake hose hold the brake hose so that it may not be...

Page 184: ...uid DOT 4 0 W Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the...

Page 185: ...er level Fill up Refer to BRAKE FLUID LEVEL INSPEC TION section in the CHAPTER 3 4 Install Diaphragm Reservoir tank cap 1 C CCAUTION After installation while pulling the lever in or pushing down on the pedal check whether there is any brake fluid leaking where the union bolts are installed respec tively at the master cylinder and caliper A Front B Rear CHAS ...

Page 186: ...er to FRONT WHEEL AND REAR WHEEL section Clamp front brake hose 1 Front fender 1 2 Pinch bolt steering damper stay 1 Only loosening left side only 3 Pinch bolt handle bracket 2 Only loosening 4 Pinch bolt handle crown 1 Only loosening 5 Cap bolt 1 Loosen when disassembling the front fork 6 Pinch bolt under bracket 1 Only loosening 7 Front fork 1 W Support the machine securely so there is no danger...

Page 187: ...MBLY 1 Cap bolt 1 Use special tool Refer to REMOVAL POINTS 2 Spacer 1 3 Spacer guide 1 4 Fork spring 1 Drain the fork oil 5 Inner tube 1 6 Stopper ring 1 Refer to REMOVAL POINTS 7 Oil seal 1 8 Oil seal washer 1 9 Bolt damper rod 1 Use special tool 0 Damper rod 1 Refer to REMOVAL POINTS CHAS T 40 Nm 4 0 mdkg 29 ftdlb T 23 Nm 2 3 mdkg 17 ftdlb T 15 Nm 1 5 mdkg 11 ftdlb 1 2 ...

Page 188: ...material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disas sembled and reassembled Before removing the cap bolts or front forks be sure to extract the air from the air chamber completely EC553000 REMOVAL POINTS EC553143 Cap bolt 1 Remove Cap bolt 1 From the outer tube NOTE Before removing the front fork from the machine loosen the...

Page 189: ...spring preload adjuster 6 Fork spring compressor YM 01441 90890 01441 Rod holder YM 01434 90890 01434 C EC553212 Oil seal 1 Remove Inner tube 1 Pull out the inner tube from the outer tube 2 2 Remove Stopper ring 1 Using slotted head screwdriver 3 Remove Oil seal 1 Oil seal washer Using slotted head screwdriver C CCAUTION Take care not to scratch the outer tube inner surface Replace the oil seal wh...

Page 190: ...eplace damper rod C CCAUTION The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled EC554400 Fork spring 1 Measure Fork spring free length a Out of specification Replace Fork ...

Page 191: ... dial gauge 1 Inner tube bending limit 0 2 mm 0 008 in a NOTE The bending value is shown by one half of the dial gauge reading W Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube EC554611 Outer tube 1 Inspect Outer tube 1 Piston metal 2 Slide metal 3 Damage Score marks Wear Replace outer tube assembly EC554710 Cap bolt 1 Inspect Cap bolt 1 O ring 2 Wear Damage ...

Page 192: ...d into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install Copper washer 1N Bolt damper rod 2 To inner tube 3 4 Tighten Bolt damper rod 1 GT40 Nm 4 0 mdkg 29 ftdlb NOTE Use a damper rod holder 3 to lock the damper rod 2 Damper rod holder YM 01425 90890 01425 A 5 Install Locknut 1 To damper rod 2 CHAS ...

Page 193: ...l with its manufacture s marks or number facing the axle holder side 7 Install Inner tube 1 To outer tube 2 C CCAUTION When installing the inner tube slowly and take care to insert it carefully so that the slide metal 3 3 and piston metal 4 4 will not be scratched 8 Install Oil seal washer 1 To outer tube slot 9 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2...

Page 194: ...ecommended oil Suspension oil 01 0 C CCAUTION Be sure to use recommended fork oil If other oils are used they may have an excessively adverse effect on the front fork performance Never allow foreign materials to enter the front fork CHAS 14 After filling pump the damper rod 1 slowly up and down more than 10 times to distrib ute the fork oil NOTE Use the rod puller 2 and rod puller attachment 3 to ...

Page 195: ...el NOTE Fill with the fork oil up to the top end of the outer tube or the fork oil will not spread over to every part of the front forks thus making it impossible to obtain the correct level Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks 18 Measure Oil level left and right a Out of specification Adjust Standard oil level 110 mm 4 33 in Extent of adjustm...

Page 196: ... holder between the locknut 6 and spacer Rod puller 1 1 YM 01437 90890 01437 Rod puller attachment 2 2 90890 01436 Fork spring compressor 3 3 YM 01441 90890 01441 Rod holder 4 4 YM 01434 90890 01434 g 21 Adjust Distance a Out of specification Turn the locknut 2 until the specified distance is obtained Distance a a 13 mm 0 51 in Between damper rod 1 1 top and locknut 2 2 top c 22 Adjust Rebound dam...

Page 197: ...ter 4 with your hand until the rebound damping adjuster 3 hits the push rod tip 24 Check Cap bolt clearance a Out of specification Repeat the steps 21 to 23 Cap bolt clearance a a Zero 2 mm Zero 0 08 in a C CCAUTION If the cap bolt is installed out of specifica tion proper damping force cannot be obtained 25 Install Cap bolt locknut 1 T15 Nm 1 5 mdkg 11 ftdlb NOTE Hold the locknut 2 and tighten th...

Page 198: ...lt under bracket Do not tighten the pinch bolts handle crown steering damper stay and handle bracket yet 2 Tighten Cap bolt 1 T23 Nm 2 3 mdkg 17 ftdlb 3 Adjust Front fork top end a Handlebar position b Steering damper stay position c left side only Front fork top end 18 mm 0 71 in Handlebar position 20 mm 0 79 in Steering damper stay position Zero mm Zero in e Refer to FRONT FORK TOP END ADJUSTMEN...

Page 199: ...fer to FRONT FORK TOP END ADJUSTMENT in the CHAPTER 3 5 Check Steering smooth action Turn the handlebar to make sure no parts are being contacted with others Contact Repair 6 Adjust Rebound damping force Spring preload NOTE Turn in the rebound damping adjuster 1 fully then turn out it to the originally set position Turn in the spring preload adjuster 2 to the originally set position 7 Install Fron...

Page 200: ...in the CHAPTER 4 1 Clutch cable 1 Disconnect at the lever side 2 Clutch lever holder 1 3 ENGINE STOP button 1 4 Grip left 1 Refer to REMOVAL POINTS 5 Master cylinder 1 6 Grip cap upper 1 7 Throttle cable 1 8 Throttle 1 9 Grip cap lower 1 10 Grip end 2 11 Handlebar 2 12 Grip right 1 Refer to REMOVAL POINTS 13 Tube guide 1 CHAS T 5 Nm 0 5 mdkg 3 6 ftdlb T 8 Nm 0 8 mdkg 5 8 ftdlb T 8 Nm 0 8 mdkg 5 8 ...

Page 201: ...ten a bent handle bar as this may dangerously weaken the handlebar EC5B5000 ASSEMBLY AND INSTALLATION EC5B5110 Throttle assembly 1 Install Ring plate 1 Grip right 2 Apply the adhesive on the tube guide 3 NOTE Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac quer thinner EC5B5220 Handlebar 1 Install Handlebar 1 Bolt handlebar 2 T8 Nm 0 8 mdkg 5 8 ftdlb Grip...

Page 202: ...NOTE Apply the lithium soap base grease on the throttle cable end and tube guide cable widing portion Install the throttle cable in the grip side slit a in the tube guide 5 Install Grip cap upper 1 Bolt grip cap 2 NOTE Align the contacting surface a of the grip cap upper with the punch mark b on the han dlebar Tighten the bolts so that the front side con tacting surface c is closed 6 Adjust Thrott...

Page 203: ...mark c on the han dlebar 8 Install Grip left 1 Apply the adhesive to the handlebar 2 NOTE Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner 9 Install ENGINE STOP button 1 Clutch lever holder 2 Bolt clutch lever holder 3 T5 Nm 0 5 mdkg 3 6 ftdlb NOTE The ENGINE STOP button and clutch lever holder should be installed according to the dimensions sh...

Page 204: ... 5 43 11 Adjust Clutch lever free play Refer to CLUTCH ADJUSTMENT section in the CHAPTER 3 12 Lock the throttle cables using a locking wire Refer to LOCKING WIRE INSTALLATION GUIDE section in the CHAPTER 3 CHAS ...

Page 205: ... the CHAPTER 4 Bolt Front brake reservoir tank Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front fender 1 Steering shaft nut 1 2 Pinch bolt handle crown 2 Only loosening 3 Handle crown 1 4 Clip 1 5 Bolt steering damper 1 6 Steering damper 1 7 Steering damper bracket 1 W Support the machine securely so there is no danger of...

Page 206: ...ing 5 Front fork 2 Refer to FRONT FORK section 6 Ring nut 1 Use special tool Refer to REMOVAL POINTS 7 Under bracket 1 8 Inner fender 1 9 Ball race cover 1 10 Bearing upper 1 11 Bearing lower 1 Refer to REMOVAL POINTS 12 Ball race 2 Refer to REMOVAL POINTS CHAS T 8 Nm 0 8 mdkg 5 8 ftdlb T 20 Nm 2 0 mdkg 14 ftdlb T 8 Nm 0 8 mdkg 5 8 ftdlb T 20 Nm 2 0 mdkg 14 ftdlb T 7 Nm 0 7 mdkg 5 1 ftdlb t TIGHTE...

Page 207: ...ring shaft so that it may not fall down EC563300 Bearing lower 1 Remove Bearing lower 1 Use the floor chisel 2 C CCAUTION Take care not to damage the steering shaft thread EC563400 Ball race 1 Remove Ball race 1 Remove the ball race using long rod 2 and the hammer EC564000 INSPECTION EC564200 Steering shaft 1 Inspect Steering shaft 1 Bend Damage Replace CHAS ...

Page 208: ...ll races as a set EC564300 Steering damper 1 Inspect Steering damper 1 Bend Damage Replace Oil leaks Unsmooth movement Replace EC565000 ASSEMBLY AND INSTALLATION EC565182 Under bracket 1 Install Bearing lower 1 NOTE Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install Inner fender 1 Screw inner fender 2 To under bracket 3 NOTE Install the inner fender w...

Page 209: ...N AND ADJUSTMENT section in the CHAP TER 3 6 Check the steering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 7 Install Front fork 1 Steering damper stay 2 left side only Handlebar 3 Handle crown 4 NOTE Temporarily tighten the pinch bolt under bracket Do not tighten the pinch bolts handle crown steering damper stay and...

Page 210: ...nut little by lit tle 10 Install Steering damper bracket 1 Pinch bolt steering damper bracket 2 T5 Nm 0 5 mdkg 3 6 ftdlb To steering damper 3 NOTE When installing the steering damper bracket provide a distance a of 9 mm 0 35 in from its edge C CCAUTION Tighten the pinch bolt to specified torque If torqued too much it may cause the steer ing damper to malfunction CHAS 11 Install Pin 1 Plain washer ...

Page 211: ...END ADJUSTMENT in the CHAPTER 3 13 Tighten Pinch bolt handle crown 1 T15 Nm 1 5 mdkg 11 ftdlb Pinch bolt under bracket 2 T20 Nm 2 0 mdkg 14 ftdlb Pinch bolt handle bracket 3 T8 Nm 0 8 mdkg 5 8 ftdlb Pinch bolt steering damper stay 4 left side only T7 Nm 0 7 mdkg 5 1 ftdlb Refer to FRONT FORK TOP END ADJUSTMENT in the CHAPTER 3 14 Check Steering smooth action Turn the handlebar to make sure no part...

Page 212: ...in Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Rear shock absorber Refer to REAR SHOCK ABSORBER section 1 Connecting rod 2 Hold the swingarm 2 Pivot shaft adjust bolt 1 3 Pivot shaft 1 Use special tool 4 Swingarm 1 Refer to REMOVAL POINTS 5 Relay arm 1 6 Cover 2 7 Thrust bearing 2 8 Bush 1 9 Bearing 5 Refer to REMOVAL POINTS W Support the machine securely so there is no danger of it fal...

Page 213: ...wrench adapter YM 01476 90890 01476 C 2 Remove Pivot shaft 1 Swingarm 2 EC573210 Bearing 1 Remove Bearing 1 Use a general bearing puller 2 EC574010 INSPECTION Wash the bearings bushes collars and cov ers in a solvent EC574131 Swingarm 1 Inspect Bearing 1 Bush 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect Bearing 1 Collar 2 Free play exists Unsmooth revolut...

Page 214: ...lution Rust Replace bearing and collar as a set EC574320 Connecting rod 1 Inspect Connecting rod 1 Wear Damage Replace EC574520 Swingarm side clearance 1 Measure Bush length a 2 Measure Thrust bearing right thickness b Thrust bearing left thickness c 3 Measure Swingarm head pipe length d CHAS ...

Page 215: ...ust shim is available only in the 0 3 mm 0 012 in thick type When only one shim is required install it on the left side and when two shims are neces sary install them on both right and left sides EC575000 ASSEMBLY AND INSTALLATION EC575300 Bearing 1 Install Bearing 1 To swingarm NOTE Apply the lithium soap base grease on the bearing when installing Install the bearing by pressing it on the side ha...

Page 216: ... of bearings a a Zero mm Zero in a EC575163 Swingarm 1 Install Collar 1 To relay arm 2 NOTE Apply the lithium soap base grease on the col lars and bearings 2 Install Relay arm 1 Bolt relay arm 2 Nut relay arm 3 T34 Nm 3 4 mdkg 24 ftdlb NOTE Apply the lithium soap base grease on the bolt 3 Install Bush 1 Thrust bearing 2 Cover 3 To swingarm 4 NOTE Apply the lithium soap base grease on the bush bear...

Page 217: ...tighten the pivot adjust bolt Pivot shaft wrench YM 01455 90890 01455 Pivot shaft wrench adapter YM 01476 90890 01476 C 6 Install Plain washer 1 Nut pivot shaft 2 T63 Nm 6 3 mdkg 45 ftdlb 7 Check Swingarm side play a Free play exists Check side clearance Swingarm up and down movement b Unsmooth movement Binding Rough spots Grease or replace bearings bushes and collars 8 Install Collar swingarm 1 N...

Page 218: ...Install Connecting rod 1 Bolt connecting rod 2 Nut connecting rod 3 T34 Nm 3 4 mdkg 24 ftdlb NOTE Install the connecting rods with the mark a outward of the chassis Apply the lithium soap base grease on the bolts CHAS ...

Page 219: ...EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Rear frame 1 2 Bolt rear shock absober 1 Hold the swingarm relay arm 3 Cap 1 4 Bolt Upper bracket 1 5 Rear shock absober 1 6 Bolt rea shock absober 1 upper bracket 7 Upper bracket 1 8 Locknut 1 Loosen 9 Adjuster 1 Loosen 10 Spring guide 1 11 Spring rear shock absober 1 12 Bearing 2 Refer to REMOVAL POINTS W Support the machine securely so there ...

Page 220: ...e to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out 5 Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug 6 When scrapping the shock absorber ...

Page 221: ... Replace absorber assembly Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assembly Spring 3 Damage Replace spring Fatigue Replace spring Move spring up and down Spring guide 4 Wear Damage Replace spring guide Bearing 5 Free play exists Unsmooth revolution Rust Replace CHAS 2 Remove Bearing 1 NOTE Remove the bearing by pressing its outer race ...

Page 222: ...g when installing Install the bearing parallel until it contacts the stopper ring by pressing its outer race 2 Install Stopper ring 1N EC585130 Spring rear shock absorber 1 Install Spring 1 Spring guide 2 2 Tighten Adjuster 1 3 Adjust Spring length installed a Spring length installed a a Standard length Extent of adjustment 138mm 5 43 in 130 150 mm 5 12 5 91 in CHAS ...

Page 223: ...2 Rear shock absorber 1 Install Dust seal 1 Collar 2 NOTE Apply the lithium soap base grease on the bearings and collars 2 Install Upper bracket 1 Bolt rear shock absorber upper bracket 2 Plain washer rear shock absorber upper bracket 3 Nut rear shock absorber upper bracket 4 T34 Nm 3 4 mdkg 24 ftdlb NOTE Apply the lithium soap base grease on the bolt 3 Install Rear shock absorber 4 Install Bolt u...

Page 224: ...Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 T34 Nm 3 4 mdkg 24 ftdlb NOTE Apply the lithium soap base grease on the bolt 6 Install Rear frame 1 Bolt rear frame 2 T23 Nm 2 3 mdkg 17 ftdlb CHAS ...

Page 225: ...EC 1 CDI unit 2 Voltage regulator 3 Condenser 4 Tachometer assembly 5 ENGINE STOP button 6 Ignition coil 7 Spark pulg 8 Solenoid valve 9 CDI magneto 0 Thermo unit COLOR CODE B Black Br Brown G Green Gy Gray P Pink R Red W White B L Black Blue B W Black White G W Green White O B Orange Black W B White Black W G White Green EC612000 WIRING DIAGRAM 6 ...

Page 226: ... 1 Cowling 2 Fuel tank Use the following special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 C Check pulg cap Replace OK No good Spark gap test Clean or replace spark plug OK Spark Repair or replace Check entire ignition system for connection No good OK Replace Check ENGINE STOP button No good OK Replace CDI unit Check ignition coil OK Primary coil No good R...

Page 227: ...the spark gap except for USA and CDN Minimum spark gap 5 mm 0 2 in a EC623001 SPARK PLUG CAP INSPECTION 1 Remove Spark plug cap C CCAUTION Do not pull the spark plug lead out of the spark plug cap Turn the spark plug cap counterclockwise to remove it and clock wise to install it 2 Check Spark plug cap resistance Out of specification Replace Spark plug cap Tester selector resistance position 4 6 kΩ...

Page 228: ...ITION COIL INSPECTION 1 Inspect Primary coil resistance Out of specification Replace Tester lead Gray lead 1 1 Tester lead Black lead 2 2 Primary coil Tester selector resistance position 0 14 0 18 Ω at Ω X X 1 20 C 68 F 2 Inspect Secondary coil resistance Out of specification Replace Tester lead Spark plug lead 1 1 Tester lead Black lead 2 2 Secondary coil Tester selector resistance position 5 0 7...

Page 229: ...lector resistance position 94 140 Ω at Ω X X 100 20 C 68 F 2 Inspect Source coil resistance Out of specification Replace Tester lead White lead 1 1 Tester lead White lead 2 2 Source coil Tester selector resistance position 1 3 1 9 Ω at Ω X X 1 20 C 68 F EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again ...

Page 230: ...tion 1 Cowling 2 Fuel tank Use l2V battery in this inspection Use the following special tools in this inspection Pocket tester YU 03112 90890 03112 A Replace condenser Repair or replace Check each couplers and wire connection No good OK OK Check solenoid valve operation Check solenoid valve coil No good Replace No good Replace CDI unit OK Check CDI magneto OK Source coil No good Replace Check volt...

Page 231: ...the checking lead 2 between the wireharness 3 and battery 12V 4 Check the solenoid valve 5 operation If a click can be heard the solenoid valve is working properly No click Check the coupler and lead connection Check the solenoid valve resistance EC653002 SOLENOID VALVE COIL INSPECTION 1 Inspect Solenoid valve coil resistance Out of specification Replace Tester lead Red lead 1 1 Tester lead Red le...

Page 232: ...TION 1 Disconnect the condenser lead 2 Start the engine 3 Inspect Out put voltage Out of specification Replace voltage regulator Tester lead Red lead 1 1 Tester lead Black lead 2 2 Out put Tester selector voltage position 14 2 15 2 V at DCV 20 5 000 r min ELEC ...

Page 233: ...o SOLENOID VALVE SYSTEM section NOTE Remove the following parts before inspection 1 Cowling Use the following special tools in this inspection Pocket tester YU 03112 90890 03112 A Replace condenser or tachometer assembly Repair or replace Check each couplers and wire connection No good OK Check thermo unit Replace No good 1Check CDI magneto OK OK Source coil No good Replace 2Check voltage regulato...

Page 234: ...tester lead connected in a container containing cooling tap water 1 down to the upper threaded portion a 2 Water temperature gauge 3 Poket tester 4 Inspect Thermo unit resistance Measure the resistance while gradually heating the cooling water Out of specification Replace Cooling Thermo Tester water unit selector temperature resistance position 50 C 122 F 9 72 11 4 kΩ kΩ X X 1 80 C 176 F 3 41 4 01...

Page 235: ...uretor must be properly suited to the atmospheric conditions air pressure humidity and temperature As a basic setting method only the factory set main jet is first changed to check for the dis coloration of the spark plug s and piston s at full throttle in 6th and then the setting is deter mined at mid open throttle Recording and storing the data on the set tings weather conditions road surface co...

Page 236: ...t 12 150 rpm of the engine after which only the main jet domi nates 1 Throttle valve opening 2 Full open 3 Full closed EC71E011 Basic process of carburetor setting Ex factory setting is on the richer side which should basically have no problems with the brake in procedure Refer to STARTING AND BREAK IN section in the CHAPTER 1 1 Adjustment of main jet Use a main jet 1 with a smaller calibration nu...

Page 237: ... can be used just by looking at discoloration he should consult an experienced person for his own experience too Whether the setting is proper or not can be judged by engine revolutions Approximate criteria for such judgment are given below on condition that the sec ondary reduction ratio is fit for conditions of the circuit 13 000 rpm in 1st and 2nd 12 500 rpm in 5th and 6th A Normal B Over burne...

Page 238: ...it layouts greatly affect the jet needle setting 1 Rider who frequently uses mid open throt tle 2 Circuit that requires frequent throttle open ing and closing 3 Wet environment Conditions as mentioned above require a longer period of throttle closing resulting in the drawn in mixture staying longer in the crankcase Such setting in turn will inevitably cause the mixture to be richer at the next thr...

Page 239: ...own the needle to lean out the mixture Too lean in the mid open position The engine breathes hard and will not pick up speed quickly Step up the jet needle clip by one groove and move up the needle to enrich the mix ture Factory set clip position No 3 Groove w EC71S000 Jet needle On the carburetors used in the TZ125 the main nozzle is press fitted so it can not be replaced Therefore carburetor set...

Page 240: ... at each stage of throttle opening by the combination of the jet needle straight portion diameter taper starting position and clip position Example N8WW 3rd groove N8VW 3rd groove N8VH 2nd groove N8VH 3rd groove A Lean larger diameter B Rich smaller diameter 1 1 8 throttle 2 1 4 throttle 3 1 2 throttle a Main nozzle EC71H031 Other setting parts 1 Power jet 1 Use a power jet of a smaller size if in...

Page 241: ... for the pilot jet This setting may be changed for want of time or in emergency but it is basically set at the factory set pilot air screw position Factory set pilot air Factory set screw position w 4 Spark plug The spark plug heat range is not basically changed Constant attention to the discoloration of the spark plug and piston head will enable you to tell to some extent whether the set ting is ...

Page 242: ... 4MX 14943 45 192 4MX 14943 96 195 4MX 14943 46 198 4MX 14943 97 200 4MX 14943 47 205 4MX 14943 48 210 4MX 14943 49 215 4MX 14943 50 Rich 220 4MX 14943 51 Pilot jet 2 2 Lean 38 4SR 14948 02 40 4SR 14948 03 Rich 42 4MX 14948 04 Jet needle Lean N8VK 4JT 14916 VK 3 3 N8VJ 4JT 14916 VJ N8VW 4JT 14916 VW Rich N8VH 4JT 14916 VH Lean N8WK 4JT 14916 WK N8WJ 4JT 14916 WJ N8WW 4JT 14916 WW Rich N8WH 4JT 149...

Page 243: ...The use of the supplied gaskets of different thicknesses makes it possible to change the combustion chamber volume to deal with changing weather conditions Not much torque is felt with slow engine accel eration Reduce the combustion chamber volume Torque is felt with no higher revolutions Expand the combustion chamber volume Thickness Actual combustion Type chamber volume 0 8 mm Approx 9 42 cm3 ST...

Page 244: ...gher altitude slide to the right the tem perature scale readings by 10 C 50 F each for every change in the air pressure of 27 hPa 20 mmHg Too much random piston protrusion at low temperature may develop an abnormal combustion detonation which may adversely affect the intended performance of the engine A Air temperature B Piston protruding amount EC71T000 Cylinder gasket setting parts Part number S...

Page 245: ...mission gear ratio The following gear sets are contained in the packing or optional to allow the rider to change the gear ratios according to the circuit condition or rider s preference C CCAUTION Select the transmission gears so that the number of grooves in the wheel gear match that of the pinion gear as shown below Trouble may be occurred if the selection is different than that listed below a G...

Page 246: ...pplying part 28 22 1 278 4JT 17241 00 4JT 17131 00 Factory installed 25 20 1 250 4JT 17241 30 4JT 17131 30 Supplying part 27 22 1 227 4JT 17241 10 4JT 17131 10 1 5th gear Gear ratio Part number Number of groove Factory installed 24 21 1 143 4JT 17251 30 4JT 17151 20 2 Supplying part 26 23 1 130 4JT 17251 10 4JT 17151 10 1 6th gear Gear ratio Part number Number of groove Factory installed 26 24 1 0...

Page 247: ...20 24T 4JT 17161 30 27T 4JT 17161 11 1st wheel gear 6 6 29T 4JT 17211 10 30T 4JT 17211 00 2nd wheel gear 7 7 27T 4JT 17221 10 31T 4JT 17221 30 35T 4JT 17221 00 3rd wheel gear 8 8 23T 4JT 17231 00 24T 4JT 17231 30 25T 4JT 17231 20 26T 4JT 17231 10 4th wheel gear 9 9 24T 4JT 17241 20 25T 4JT 17241 30 27T 4JT 17241 10 28T 4JT 17241 00 5th wheel gear 0 0 24T 4JT 17251 30 26T 4JT 17251 10 30T 4JT 17251...

Page 248: ...rce adjustment and if this not enough then adjust the machine height On the side where the machine height is greater the stroke increases whereas it decreases on the side with a smaller machine height If the damping force is increased either on the compression or the expansion side it results in less smooth movement so do not depart too far from the standard settings Adjust the machine height in a...

Page 249: ...s 2 mm 0 08 in smaller raise the rear posture by 2 mm 0 08 in by decreasiry the adjuster set length b by 1 mm 0 04 in NOTE Find the tire radius by calculating the mea sured circumference of the tire A change of 1 mm 0 04 in in the front fork top end results in a change of about 1 mm 0 04 in in the front posture A change of 1 mm 0 04 in in the adjuster set length results in a change of about 2 mm 0...

Page 250: ...the rear shock absorber rod 2 Settings At the beginning of the break in period always record the remaining stroke as data To judge front and rear balance in relation to the machine height the usual way is to shift from full braking to turning and get the feel when the clipper riding After making an actual run proceed to the settings for a target of a 5 10 mm 0 20 0 39 in remaining stroke for front...

Page 251: ... 1 5 mm 0 06 in Too stiff from the beginning and not smooth in mid range as well Decrease damping force on compression side Front Every one turn Rear Every two clicks Unstable and spongy Increase damping force both on compression and rebound Front Every one turn Rear Every two clicks Check stroke YES NO NO NOTE Preload increase results in relative lack of damping force If the preload is increased ...

Page 252: ...er speed ratio The smaller value the lower speed ratio EC72N000 Drive and driven sprockets setting parts Part name Size Part number Drive sprocket 1 1 16T 938AA 16198 17T 938AA 17196 18T 938AA 18199 Driven sprocket 2 2 35T 4JT 25435 20 36T 4JT 25436 20 37T 4JT 25437 20 38T 4JT 25438 20 39T 4JT 25439 20 Driven sprocket 35T 36T 37T 38T 39T Drive sprocket 16T 2 188 2 250 2 313 2 375 2 438 17T 2 059 2...

Page 253: ...ration Check the shock absorber feeling Check rod inner tube etc for bending If bent replace Check for any deviation from center after tightening front wheel axle Replace if deviated in any way Too much tightened bolts for front fork outer tube Retorque the bolts to specification handle crown under bracket steering damper stay handlebar Too stiff poor stroke Decrease spring preload Decrease dampin...

Page 254: ...oo big caster angle Decrease damping force for rebound for rear Increase front fork top end Decrease spring preload for front Too much knifing Machine tend to incline Decrease front fork top end at cornering too much forward Decrease rear height Too small caster angle Increase spring preload for front Increase damping force for compression for front Front dives in too early Increase damping force ...

Page 255: ...ming Spark plug Carburetor Main jet Power jet Jet needle Pilot jet Pilot air screw Float height Gearing 1st 2nd 3rd 4th 5th 6th Secondary Front fork Spring rate Spring preload Rebound damping Compression damping Top end Oil capacity Oil level Rear shock Spring fitting length Spring rate Rebound damping Compression damping Seat height Front tire pressure Rear tire pressure Fuel consumption ...

Page 256: ...ad Rebound damping Compression damping Top end Oil capacity Oil level Rear shock Spring fitting length Spring rate Rebound damping Compression damping Seat height Front tire pressure Rear tire pressure Fuel consumption NOTE 1 Make setting changes in small increments 2 When the proper settings have been determined for a particular track they should be written down for reference upon returning to th...

Page 257: ...99 8 0 1x1 ...

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