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Yamaha WR450F(R), Owner'S Service Manual

The Yamaha WR450F(R) Owner's Service Manual is a comprehensive manual designed to assist owners in maintaining and servicing their WR450F(R) model. This invaluable manual can be downloaded for free from manualshive.com, providing easy access to all the necessary information needed to keep your Yamaha motorcycle in optimal condition.

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CHAS

EC553201

Inner tube

1. Remove:

●

Dust seal 

1

 

●

Stopper ring 

2

 

Using slotted-head screwdriver.

ACHTUNG:

CAUTION:

Take care not to scratch the inner tube.

2. Remove:

●

Inner tube 

1

 

Oil seal removal steps:

●

Push in slowly 

a

 the inner tube just before

it bottoms out and then pull it back quickly

b

.

●

Repeat this step until the inner tube can
be pulled out from the outer tube.

EC553311

Damper rod

1. Remove:

●

Base valve 

1

 

●

Damper rod 

2

 

NOTE:

Use a damper rod holder 

3

 to lock the damper

rod.

EC554000

INSPECTION

EC554100

Damper rod

1. Inspect:

●

Damper rod 

1

 

Bend/damage 

→

 Replace damper rod.

ACHTUNG:

CAUTION:

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.

Damper rod holder:

YM-1423/90890-01423

FRONT FORK

Summary of Contents for WR450F(R)

Page 1: ...LIT 11626 16 43 WR450FR 5TJ 28199 10 OWNER S SERVICE MANUAL ...

Page 2: ......

Page 3: ...002 by Yamaha Motor Corporation U S A 1st Edition October 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 43 ...

Page 4: ...please contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING 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 A...

Page 5: ......

Page 6: ... PROTECTIVE APPAREL 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 maintained...

Page 7: ...s Carbon monoxide is a dangerous gas which can cause unconscious ness 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 THE ENGINE EXHAUST PIPE MUF FLER AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN Be careful not to touch them or to...

Page 8: ...his machine and should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become out dated 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 EC070001 F I M MACHINE WEIGHTS Weights of machines without fuel The minimum weights for motocross ma...

Page 9: ... avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer WARNING CAUTION 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 lay out of the bo...

Page 10: ... start of each removal and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the use of symbol marks 3 The meanings of the symbol marks a...

Page 11: ...ubricant B Tightening C Specified value Service limit D Resistance Ω Voltage V Electric current A Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and loca tion of lubrication point E Apply engine oil F Apply molybdenum disulfide oil G Apply lightweight lithium soap base grease H Apply molybdenum disulfide grease Illustrated symbols I to J in the exploded diagrams in...

Page 12: ...MEMO ...

Page 13: ...EC090000 INDEX GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE ENG 4 CHASSIS CHAS 5 ELECTRICAL ELEC 6 TUNING TUN 7 GEN INFO INSP ADJ ...

Page 14: ...AK IN 1 15 TORQUE CHECK POINTS 1 19 CLEANING AND STORAGE 1 20 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 20 DEFINITION OF UNITS 2 20 LUBRICATION DIAGRAMS 2 21 CABLE ROUTING DIAGRAM 2 23 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 4 ENGINE 3 5 CHASSIS 3 26 EL...

Page 15: ... 48 OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT 4 55 BALANCER 4 62 OIL PUMP 4 65 KICK AXLE AND SHIFT SHAFT 4 69 AC MAGNETO AND STARTER CLUTCH 4 76 ENGINE REMOVAL 4 83 CRANKCASE AND CRANKSHAFT 4 89 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 98 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT BRAKE AND REAR BRAKE 5 11 FRONT FORK 5 27 HANDLEBAR 5 40 STEERING 5 46 SWINGARM 5 52 REAR SHOCK ABSOR...

Page 16: ...COMPONENTS AND WIRING DIAGRAM 6 1 MAP CONTROLLED CDI UNIT 6 2 IGNITION SYSTEM 6 3 ELECTRIC STARTING SYSTEM 6 7 CHARGING SYSTEM 6 17 TPS THROTTLE POSITION SENSOR SYSTEM 6 19 LIGHTING SYSTEM 6 24 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 10 ...

Page 17: ... A Fuel tank cap B Taillight C Kickstarter D Fuel tank E Headlight F Radiator G Coolant drain bolt H Rear brake pedal I Valve joint J Fuel cock K Cold starter knob L Air cleaner M Drive chain N Shift pedal O Oil dipstick P Front fork NOTE The machine you have purchased may differ slightly from those shown in the following Designs and specifications are subject to change without notice B C D E F G ...

Page 18: ...ne is stolen the authorities will need the number to search for and identify your machine EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe 1 EC123001 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine 1 EC124000 MODEL LABEL The model label 1 is affixed to the f...

Page 19: ...in hole on the cylinder head right side All electrical components 2 Use proper tools and cleaning equip ment Refer to SPECIAL TOOLS sec tion 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During the machine disassembly clean all par...

Page 20: ... EC134000 LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates 1 and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or num bers facing outward In other words the stamped lette...

Page 21: ...ould be inspected carefully before reassembly Always replace pis ton pin clips after one use Replace dis torted circlips When installing a circlip 1 make sure that the sharp edged cor ner 2 is positioned opposite to the thrust 3 it receives See the sectional view 4 Shaft ...

Page 22: ...o check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the con nector 6 Connect Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE If there in 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 ava...

Page 23: ... Stand These tools are used to check each part for runout or bend YU 3097 YU 1256 90890 01252 YU 90050 90890 01274 YU 90050 90890 01275 YM 91044 90890 04081 YU 90063 90890 01278 Crankshaft installing tool Crankshaft installing pot Crankshaft installing bolt Spacer crankshaft installer Adapter M12 These tools are used to install the crankshaft YU 90050 YU 90063 YM 91044 90890 01274 90890 01275 9089...

Page 24: ...e valve assemblies YM 4019 90890 04019 YM 91042 90890 04086 Clutch holding tool This tool is used to hold the clutch when removing or installing the clutch boss securing nut YM 91042 90890 04086 YM 4116 90890 04116 YM 4097 90890 04097 Valve guide remover Intake 4 5 mm 0 18 in Exhaust 5 0 mm 0 20 in This tool is needed to remove and install the valve guide YM 4116 YM 4097 90890 04116 90890 04097 YM...

Page 25: ...7 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 This sealant Bond is used for crankcase mating surface etc ACC QUICK GS KT 90890 85505 Part number Tool name How to use Illustration ...

Page 26: ... the main switch ON It goes out when the engine increases its speed after being started It lights up again when the engine is stopped NOTE If the indicator light will not light up with the main switch ON it shows a lack of the battery voltage Recharge the battery If the engine is kick started turn off the light switch EC151000 ENGINE STOP BUTTON The ENGINE STOP button 1 is located on the left hand...

Page 27: ...ne EC154000 KICKSTARTER Rotate the kickstarter 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primary kickstarter so the engine can be started in any gear if the clutch is disengaged In normal practices however shift to neutral before starting 1 EC155001 THROTTLE GRIP The throttle gri...

Page 28: ...ve section of the fuel tank after the main supply of the fuel has been depleted Normal riding is possible with the lever is in this position but it is recommended to add fuel as soon as possible COLD STARTER KNOB When cold the engine requires a richer air fuel mixture for starting A separate starter circuit which is controlled by the cold starter knob 1 supplies this mixture Pull the cold starter ...

Page 29: ...uel from flowing out and is installed to the fuel tank breather hose CAUTION In this installation make sure the arrow faces the fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug 1 1 NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke CONTROL FUNCTIONS ...

Page 30: ...n rings and exhaust system etc NOTE If knocking or pinging occurs use a different brand of gasoline or higher octane grade WARNING For refueling be sure to stop the engine and use enough care not to spill any fuel Also be sure to avoid refueling close to a fire Refuel after the engine exhaust pipe etc have cooled off Recommended fuel Except for ZA Premium unleaded gasoline only with a research oct...

Page 31: ...fore starting the machine perform the checks in the pre operation check list AIR FILTER MAINTENANCE According to AIR FILTER CLEANING section in the CHAPTER 3 apply the foam air filter oil or its equivalent to the element Excess oil in the element may adversely affect engine start ing STARTING A COLD ENGINE NOTE This model is equipped with an ignition circuit cut off system The engine can be starte...

Page 32: ...n pushing the start switch stop pushing it immediately and kick start the engine in order to avoid the load on the motor Do not open the throttle while kicking the kickstarter Otherwise the kickstarter may kick back 7 Return the cold starter knob to its original position and run the engine at 3 000 5 000 r min for 1 or 2 minutes NOTE Since this model is equipped with an accelera tor pump if the en...

Page 33: ...olding the lever kick the kickstarter 10 to 20 times to clear the engine Then restart the engine Refer to Restarting an engine after a fall Operate the throttle grip before kick starting CAUTION Observe the following break in procedures during initial operation to ensure optimum performance and avoid engine damage Throttle grip oper ation Cold starter knob Hot starter lever Starting a cold engine ...

Page 34: ... speed for about one hour 6 Restart the engine and check the opera tion of the machine throughout its entire operating range Restart the machine and operate it for about 10 to 15 more minutes The machine will now be ready to race CAUTION After the break in or before each race you must check the entire machine for loose fittings and fasteners as per TORQUE CHECK POINTS Tighten all such fasteners as...

Page 35: ...f pivot shaft Tightening of front axle Tightening of axle holder Tightening of rear axle Wheel to sprocket Caliper to front fork Brake disc to wheel Tightening of union bolt Master cylinder to handlebar Tightening of air bleeder Brake pedal to frame Brake disc to wheel Tightening of union bolt Master cylinder to frame Tightening of air bleeder Fuel tank to fuel cock Tightening of oil hose clamp Fr...

Page 36: ...use only enough pressure to do the job CAUTION Excessive hose pressure may cause water seepage and contamination of 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...

Page 37: ...our a table spoon of SAE 10W 30 motor oil in the spark plug hole and reinstall the plug With the engine stop switch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thor oughly 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...

Page 38: ...quid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 449 cm3 15 8 Imp oz 15 2 US oz Bore stroke 95 0 63 4 mm 3 74 2 50 in Compression ratio 12 5 1 Starting system Kick and electric starter Lubrication system Dry sump Oil type or grade Engine oil For USA and CDN At 5 C 40 F or higher Å Yamalube 4 20W 40 or SAE 20W 40 type SG motor oil Non Friction modified At...

Page 39: ...Manufacturer KEIHIN Spark plug Type manufacturer CR8E NGK resistance type Gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 62 22 2 818 Secondary reduction system Chain drive Secondary reduction ratio 50 14 3 571 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 29 12 2 416 2nd 26 15 1 7...

Page 40: ... monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 300 mm 11 8 in Rear wheel travel 315 mm 12 4 in Electrical Ignition system CDI Generator system AC magneto Battery type YTZ7S Battery voltage capacity 12 V 6 AH Specific gravity 1 310 Headlight type Quartz bulb halogen Bulb wattage quantity...

Page 41: ...ide diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft journal diameter 21 967 21 980 mm 0 8648 0 8654 in Shaft to cap clearance 0 020 0 054 mm 0 0008 0 0021 in 0 08 mm 0 003 in Cam dimensions Intake A 31 200 31 300 mm 1 2283 1 2323 in 31 100 mm 1 2244 in B 22 550 22 650 mm 0 8878 0 8917 in 22 450 mm 0 8839 in Exhaust A 30 950 31 050 mm 1 2185 1 2224 in 30 850 mm 1 2146 in B 22 494 22 594 mm 0 88...

Page 42: ...0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 1 mm 0 0394 in 0 85 mm 0 033 in EX 1 mm 0 0394 in 0 85 mm 0 033 in Stem outside diameter IN 4 475 4 490 mm 0 1762 0 1768 in 4 445 mm 0 1750 in EX 4 965 4 980 mm 0 1955 0 1961 in 4 935 mm 0 1943 in Guide inside diameter IN 4 500 4 512 mm 0 1772 0 1776 in 4 550 mm 0 1791 in EX 5 000 5 012 mm 0 1969 0 1973 in 5 050 mm 0 1...

Page 43: ...kg at 27 38 mm 28 66 32 85 lb at 1 08 in Tilt limit IN 2 5 1 61mm 2 5 0 063 in EX 2 5 1 65 mm 2 5 0 065 in Direction of winding top view IN Clockwise EX Clockwise Piston Piston to cylinder clearance 0 040 0 065 mm 0 0016 0 0026 in 0 1 mm 0 004 in Piston size D 94 945 94 960 mm 3 738 3 739 in Measuring point H 8 mm 0 315 in Piston off set 1 mm 0 0394 in Piston pin bore inside diameter 18 004 18 015...

Page 44: ... 0 020 in 0 85 mm 0 033 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimensions B T 2 0 2 9 mm 0 08 0 11 in End gap installed 0 2 0 5 mm 0 01 0 02 in Crankshaft Crank width A 61 95 62 00 mm 2 439 2 441 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 002 in Big end side clearance D 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Small end free play F 0 4 1 0 mm 0 02 0 04 ...

Page 45: ...ter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Ratchet type Carburetor USA EUROPE CDN AUS NZ ZA I D mark 5TJ1 00 5TJ2 10 Main jet M J 150 160 Main air jet M A J ø2 0 Jet needle clip position J N OBDUT 4 OBDUQ 4 Cutaway C A 1 5 Pilot jet P J 45 48 Pilot air jet P A J 70 80 Pilot outlet P O ø0 9 Pilot screw example P S 1 3 4 1 1 2 Bypass B P ø1 0 Va...

Page 46: ... 0 24 mm 0 009 in Side clearance 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 007 in Bypass valve setting pressure 40 80 kPa 0 4 0 8 kg cm2 5 69 11 38 psi Cooling Radiator core size Width 127 8 mm 5 0 in Height 260 mm 10 2 in Thickness 32 mm 1 26 in Radiator cap opening pressure 110 kPa 1 1 kg cm2 15 6 psi Radiator capacity total 0 78 L 0 69 Imp qt 0 82 US qt Water pump Type Single suction centrifugal ...

Page 47: ...andard Lubrication chart Pressure feed Splashed scavenge Oil strainer Oil pan Oil pump rotor 2 Oil pump rotor 1 Oil tank Oil filter Check ball Cylinder head Crank pin Piston pin Piston Drive axle Main axle Transmission gears Camshaft Valve lifter ...

Page 48: ... M6 1 0 1 10 1 0 7 2 Carburetor joint clamp cylinder head side M5 0 8 1 3 0 3 2 2 Carburetor joint clamp carburetor side M4 0 7 1 3 0 3 2 2 Air filter case M6 1 0 2 8 0 8 5 8 Air filter joint clamp M6 1 0 1 3 0 3 2 2 Air filter joint and air filter case M5 0 8 1 4 0 4 2 9 Throttle cable pull M6 1 0 1 4 0 4 2 9 Throttle cable return M12 1 0 1 11 1 1 8 0 Throttle cable cover M5 0 8 2 4 0 4 2 9 Hot s...

Page 49: ... 1 10 1 0 7 2 Oil drain bolt crankcase rear M10 1 25 1 20 2 0 14 crankcase left M6 1 0 1 10 1 0 7 2 Oil drain bolt frame M8 1 25 1 23 2 3 17 Oil strainer frame M18 1 5 1 90 9 0 65 Crankcase bearing stopper M6 1 0 15 10 1 0 7 2 Drive axle oil seal stopper M6 1 0 2 10 1 0 7 2 Ratchet wheel guide M6 1 0 2 12 1 2 8 7 Stopper plate M6 1 0 2 12 1 2 8 7 Kickstarter M8 1 25 1 33 3 3 24 Screw kickstarter M...

Page 50: ... Min Max From top of outer tube with inner tube and damper rod fully com pressed without spring 80 150 mm 3 15 5 91 in Oil grade Suspension oil 01 Inner tube outer diameter 46 mm 1 81 in Front fork top end Zero mm Zero in Rear suspension USA CDN EUROPE AUS NZ ZA Shock absorber travel 132 mm 5 20 in Spring free length 260 mm 10 24 in Fitting length 246 mm 9 69 in 246 5 mm 9 70 in Min Max 240 5 258 ...

Page 51: ...ad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness 245 4 0 mm 9 65 0 16 in 245 3 5mm 9 65 0 14 in Deflection limit 0 15 mm 0 006 in Pad thickness 6 4 mm 0 25 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 25 ...

Page 52: ... mounting M5 0 8 2 4 0 4 2 9 Hot starter lever mounting M5 0 8 1 2 0 2 1 4 Lights switch M4 0 7 2 2 0 2 1 4 Front brake master cylinder and bracket M6 1 0 2 9 0 9 6 5 Front brake master cylinder cap M4 0 7 2 2 0 2 1 4 Brake lever mounting bolt M6 1 0 1 6 0 6 4 3 Brake lever mounting nut M6 1 0 1 6 0 6 4 3 Brake lever position locknut M6 1 0 1 5 0 5 3 6 Hose guide front brake hose M5 0 8 2 4 0 4 2 ...

Page 53: ... 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10 1 25 1 53 5 3 38 Rear frame and frame upper M8 1 25 1 32 3 2 23 Rear frame and frame lower M8 1 25 2 29 2 9 21 Swingarm and brake hose holder M5 0 8 4 1 0 1 0 7 Swingarm and patch M4 0 7 4 2 0 2 1 4 Drive chain tensioner mounting upper M8 1 25 1 19 ...

Page 54: ...ht body and headlight unit M6 1 0 2 7 0 7 5 1 Headlight mounting left and right M6 1 0 2 10 1 0 7 2 Headlight mounting lower M6 1 0 1 7 0 7 5 1 Taillight mounting M6 1 0 3 4 0 4 2 9 Taillight lead clamp and rear fender M4 1 59 2 0 5 0 05 0 36 Coolant reservoir tank mounting M6 1 0 2 7 0 7 5 1 Sidestand bracket mounting M10 1 25 2 66 6 6 48 Sidestand mounting M10 1 25 1 64 6 4 46 Part to be tighten...

Page 55: ...r min Charging coil resistance color 0 288 0 432 Ω at 20 C 68 F White Ground Lighting coil resistance color 0 224 0 336 Ω at 20 C 68 F Yellow Ground Rectifier regulator Regulator type Semiconductor short circuit Model manufacture SH712AA SHINDENGEN Regulated voltage AC 13 0 14 0 V Regulated voltage DC 14 1 14 9 V Rectifier capacity AC 12 A Rectifier capacity DC 8 A Electric starting system Type Co...

Page 56: ...ing circuit cut off relay Model manufacturer ACM33221 M06 MATSUSHITA Coil winding resistance 75 69 92 51 Ω at 20 C 68 F Fuse amperage quantity Main fuse 10 A 1 Reserve fuse 10 A 1 Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Stator M5 0 8 2 7 0 7 5 1 Holder AC magneto lead M5 0 8 2 7 0 7 5 1 Rotor M12 1 25 1 Refer to NOTE Neutral switch M5 0 8 2 4 0 4 2 9 Starter motor M6 ...

Page 57: ...y threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter EC230000 DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFICATION Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 4 3 11 22 40 61 94 Unit Read Definition Measure mm cm millimeter centimeter 10 3 meter 10 2 meter Length Leng...

Page 58: ... 21 SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 Intake camshaft 3 Exhaust camshaft 4 Oil cleaner element 5 Oil pump 6 Main axle 7 Drive axle 7 6 5 4 3 2 1 4 5 A A D D G G D D A A ...

Page 59: ...2 22 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Connecting rod 3 Oil cleaner element 4 Crankshaft 5 Main axle 6 Drive axle 7 Oil delivery pipe 1 2 3 4 5 6 7 ...

Page 60: ...k breather hose Å Insert the fuel tank breather hose into the hole in the steering shaft cap ı Fasten the diode of the wire har ness and rectifier regulator lead at its protecting tube to the frame at the white tape for the diode with a plastic locking tie and cut off the tie end Ç Fasten the wire harness recti fier regulator lead coolant res ervoir hose and hot starter cable to the frame with a p...

Page 61: ... the frame with a plastic band Pass the cylinder head breather hose on the outside of the radiator hose 1 and on the inside of the radiator pipe radi ator hose 4 ˆ Pass the oil tank breather hose on the outside of the AC mag neto lead neutral switch lead lights switch lead wire harness and cylinder head breather hose Ø Pass the wire harness on the outside of the neutral switch lead and AC magneto ...

Page 62: ...adiator mounting boss Ç Pass the throttle cables and clutch cable on the outside of the ignition coil Î Pass the carburetor breather hose throttle cable cover through the hose holder Fasten the coolant reservoir tank breather hose and carburetor breather hoses together with a plastic locking tie Ï Fasten the grommet of the clutch cable with the cable holder Ì Fasten the CDI unit lead to the frame ...

Page 63: ...ortion directs as shown and lightly touches the projection on the caliper ı Pass the brake hose into the brake hose holders Ç If the brake hose contacts the spring rear shock absorber cor rect its twist Î Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the master cylinder ...

Page 64: ...Fasten the wire harness to the frame with a plastic locking tie and cut off the tie end Ç Do not allow the taillight lead to slacken Î Pass the starter motor lead and negative battery lead over the car buretor Fasten the coolant reservoir tank breather hose coolant reservoir hose and rectifier regulator lead to the frame with a plastic band Ï Fasten the coolant reservoir tank breather hose and coo...

Page 65: ...ad and lights switch lead to the handlebar with a plastic band ı Fasten the ENGINE STOP but ton lead and clutch switch lead to the handlebar with the plastic bands Ç Pass the brake hose through the hose guide Î Pass the start switch lead in front of the main switch lead Fasten the start switch lead to the handlebar with a plastic band Ï Pass the hot starter cable and lights switch lead between the...

Page 66: ...pect Replace The engine must be cold Check the valve seats and valve stems for wear VALVE SPRINGS Inspect Replace Check the free length and the tilt VALVE LIFTERS Inspect Replace Check for scratches and wear CAMSHAFTS Inspect Replace Inspect the camshaft sur face Inspect the decompres sion system CAMSHAFT SPROCKETS Inspect Replace Check for wear on the teeth and for damage PISTON Inspect Clean Rep...

Page 67: ...ration Replace coolant Inspect hoses Every two years OUTSIDE NUTS AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Replace Use foam air filter oil or equivalent oil OIL FILTER Replace OIL STRAINER frame Clean FRAME Clean and inspect FUEL TANK COCK Clean and inspect BRAKES Adjust lever position and pedal height Lubricate pivot point Check br...

Page 68: ...OD Inspect lube and retighten Molybdenum disulfide grease STEERING HEAD Inspect free play and retighten Clean and lube Replace bearing Lithium base grease TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connection Lubricate Yamaha cable lube ...

Page 69: ...rake P 3 26 32 Chain Check chain slack and alignment Check that the chain is lubri cated properly P 3 33 36 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 44 45 Steering Check that the handlebar can be turned smoothly and have no excessive play P 3 45 46 Front forks and rear shock absorber Check that they operate smoothly and there is no oil...

Page 70: ...t CAUTION Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water 1 Place the machine on a level place and hold it in an upright position 2 Inspect Coolant level Coolant level should be between the maximum a and minimum b marks Coolant level is below the LOW level line Add soft water tap water up to the proper level 3 Start the engine and let...

Page 71: ...Coolant reservoir hose 1 Drain the coolant completely 4 Connect Coolant reservoir hose LOW FULL COOLANT 1 5 Remove Engine guard 1 Coolant drain bolt 2 6 Remove Radiator cap Drain the coolant completely 7 Clean Cooling system Thoroughly flush the cooling system with clean tap water 8 Install Copper washer Coolant drain bolt Engine guard Bolt engine guard front Bolt engine guard rear New T R 10 Nm 1...

Page 72: ...ater soft water 2 mixing ratio 50 50 Coolant capacity 1 25 L 1 10 Imp qt 1 32 US qt Handling notes of coolant The coolant is harmful so it should be han dled with special care WARNING When coolant splashes to your eye Thoroughly wash your eye with water and see your doctor When coolant splashes to your clothes Quickly wash it away with water and then with soap When coolant is swallowed Quickly mak...

Page 73: ...l wait a few minutes until the coolant settles EC355000 RADIATOR CAP INSPECTION 1 Inspect Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits 3 Clean or replace EC356001 RADIATOR CAP OPENING PRESSURE INSPECTION 1 Attach Radiator cap tester 1 and adapter 2 NOTE Apply water on the radiator cap seal 3 Radiator cap 2 Apply the specified pressure Radiator cap tester YU 24...

Page 74: ...pter 2 3 Apply the specified pressure NOTE Do not apply pressure more than specified pressure Radiator should be filled fully 4 Inspect Pressure Impossible to maintain the specified pressure for 10 seconds Repair Radiator Radiator hose joint Coolant leakage Repair or replace Radiator hose Swelling Replace Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Standard pressure 18...

Page 75: ...peration of clutch lever 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 EC35A001 THROTTLE CABLE ADJUSTMENT 1 Check Throttle grip free play a Out of specification Adjust Throttle grip free play a 3 5 mm 0 12 0 20 in 2 Adjust Throttle grip free play Throttle grip free play adjustment steps Slide th...

Page 76: ... does not run faster 2 Apply Lithium soap base grease On the throttle cable end a 3 Install Throttle cable cap Screw throttle cable cap Cover grip cap Cover throttle cable cap T R 4 Nm 0 4 m kg 2 9 ft lb HOT STARTER LEVER ADJUSTMENT 1 Check Hot starter lever free play a Out of specification Adjust 2 Adjust Hot starter lever free play NOTE After adjustment check proper operation of hot starter Hot ...

Page 77: ... dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove Air filter case cover 1 NOTE Loosen the quick screw 2 and draw the air fil ter case cover to remove it because its claws a are inserted in the side cover as shown 2 Unhook Binder 1 3 Remove Air filter element 1 Filter guide 2 4 Clean Air filter element Clean them with solvent NOTE After cleaning remove the ...

Page 78: ...the oil left on the element surface using a clean dry cloth Excess oil in the ele ment may adversely affect engine starting 7 Install Filter guide 1 NOTE Align the projection a on filter guide with the hole b in air filter element Apply the lithium soap base grease on the matching surface c on air filter element 8 Install Air filter element 1 NOTE Align the projection a on filter guide with the ho...

Page 79: ...eration The heated oil could spurt out causing danger Wait until the oil cools down to approximately 70 C 158 F 2 Idle the engine more than 3 minutes while keeping the motorcycle upright Then stop the engine and inspect the oil level 3 Remove Oil tank cap 1 1 4 Inspect Oil level Oil level should be between maximum a and minimum b marks Oil level low Add oil to proper level NOTE When inspecting the...

Page 80: ...enter the crankcase 5 Start the engine and let it warm up for several minutes CAUTION When the oil tank is empty never start the engine Recommended oil At 5 C 40 F or higher Å Yamalube 4 20W 40 or SAE 20W 40 type SG motor oil Non Friction modified At 15 C 60 F or lower ı Yamalube 4 10W 30 or SAE 10W 30 type SG motor oil Non Friction modified and or Yamalube 4 R 15W 50 Non Friction modified Recomme...

Page 81: ... and let it warm up for several minutes 2 Stop the engine and place an oil pan under the drain bolt 3 Remove Oil tank plug 1 Oil filler cap 2 Drain bolt with gasket 3 Oil filter drain bolt O ring 4 Drain bolt with gasket 5 Drain bolt with gasket 6 Drain the crankcase and oil tank frame of its oil 4 Remove Engine skid plate Engine oil hose clamp 1 Bolt engine oil hose 2 Engine oil hose 3 Oil strain...

Page 82: ...efer to ENGINE OIL LEVEL INSPEC TION Replacement steps Remove the exhaust pipe Remove the oil filter cover 1 and oil filter element 2 Check the O rings 3 if cracked or dam aged replace them with a new one Install the oil filter element and oil filter cover T R Oil filter cover 10 Nm 1 0 m kg 7 2 ft lb Oil quantity Total amount 1 2 L 1 06 Imp qt 1 27 US qt Periodic oil change 1 0 L 0 88 Imp qt 1 06...

Page 83: ...ssure Tighten the oil gallery bolt to specification T R Oil gallery bolt 10 Nm 1 0 m kg 7 2 ft lb PILOT SCREW ADJUSTMENT 1 Adjust Pilot screw 1 Except for USA Adjusting steps NOTE To optimize the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this num ...

Page 84: ...e speed Turn the throttle stop screw 1 out b Engine idling speed 1 700 1 900 r min VALVE CLEARANCE ADJUSTMENT NOTE The valve clearance should be adjusted when the engine is cool to the touch The piston must be at Top Dead Center T D C on compression stroke to check or adjust the valve clearance 1 Remove Seat Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 2 Remove Carbur...

Page 85: ...Align the T D C mark a on the rotor with the align mark b on the crankcase cover when piston is at T D C on compression stroke NOTE In order to be sure that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cyl inder head surface as shown in the illustra tion Measure the valve clearance e using a feeler gauge 1...

Page 86: ...re vent it from falling into the crankcase Remove the valve lifters 4 and the pads 5 NOTE Place a rag in the timing chain space to prevent pads from falling into the crank case Identity each valve lifter and pad position very carefully so that they can be rein stalled in their original place Select the proper pad using the pad selecting table Pad range Pad Availability 25 increments No 120 No 240 ...

Page 87: ...ersect shows the new pad number to use NOTE Use the new pad number only as a guide when verifying the valve clearance adjust ment Install the new pads 6 and the valve lift ers 7 NOTE Apply the engine oil on the valve lifters Apply the molybdenum disulfide oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their or...

Page 88: ...g chain tensioner Refer to CAMSHAFTS section in the CHAPTER 4 NOTE Turn the crankshaft counterclockwise sev eral turns so that the installed parts settle into the right position Recheck the valve clearance If the clearance is still incorrect repeat all the clearance adjustment steps until the specified clearance is obtained VALVE CLEARANCE ADJUSTMENT ...

Page 89: ...30 235 240 1 31 1 35 240 EXHAUST MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0 05 0 09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0 10 0 14 120 125 130 135 140 145 1...

Page 90: ...tem 1 Remove Bolt spark arrester 1 1 1 2 Remove Spark arrester 1 Pull the spark arrester out of the muf fler 1 3 Clean Spark arrester Tap the spark arrester lightly then use a wire brush to remove any carbon deposits 4 Install Spark arrester Insert the spark arrester into the muffler and align the bolt holes Bolt spark arrester T R 10 Nm 1 0 m kg 7 2 ft lb SPARK ARRESTER CLEANING For USA ...

Page 91: ...ake fluid to the reservoir 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 sc...

Page 92: ...eration of the brake after bleeding the brake system EC362040 FRONT BRAKE ADJUSTMENT 1 Check Brake lever position a Brake lever position a Standard position Extent of adjustment 95 mm 3 74 in 76 97 mm 2 99 3 82 in 2 Remove Lever cover 3 Adjust Brake lever position 4 Install Lever cover Brake lever position adjustment steps Loosen the locknut 1 Turn the adjusting bolt 2 until the lever position a i...

Page 93: ...nut WARNING Adjust the pedal height between the maximum Å and the minimum ı as shown In this adjustment the bolt 3 end b should protrude out of the threaded portion 4 but not be less than 2 mm 0 08 in c away from the brake pedal 5 After the pedal height adjustment make sure that the rear brake does not drag Å ı EC365080 FRONT BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out...

Page 94: ...ston in CAUTION Do not reuse the drained brake fluid Tighten the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pads 8 and pad pin NOTE Install the brake pads with their projec tions a into the caliper recesses b Temporarily tighten the pad pin at this point Install the brake hose holder 9 and cali per 0 and tighten the pad pin A NOTE Fit the brake hose holder cut c over the...

Page 95: ...the pad pin plug B T R Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb EC366060 REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out of specification Replace as a set 2 Replace Brake pad Brake pad thickness a Standard Limit 6 4 mm 0 25 in 1 0 mm 0 04 in Brake pad replacement steps Remove the protector 1 and pad pin plug 2 Loosen the pad pin 3 Remove the rear wheel 4 and caliper 5 Ref...

Page 96: ... the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pad 0 and pad pin A NOTE Install the brake pads with their projec tions a into the caliper recesses b Temporarily tighten the pad pin at this point Install the caliper B and rear wheel C Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 Tighten the pad pin D T R Pad pin 18 Nm 1 8 m kg 13 ft lb Install the pad pin...

Page 97: ... pad insulator 1 Damage Replace EC367001 BRAKE FLUID LEVEL INSPECTION 1 Place the master cylinder so that its top is in a horizontal position 2 Inspect Brake fluid level Fluid at lower level Fill up a Lower level Å Front ı Rear WARNING Use only designated quality brake fluid to avoid poor brake performance Refill with same type and brand of brake fluid mixing fluids could result in poor brake perf...

Page 98: ...ive chain Brush off as much dirt as possible Then clean the chain using the chain cleaner CAUTION This machine has a drive chain with small rubber O rings 1 between the side plates Steam cleaning high pressure washes certain solvent and kerosene can damage these O rings 1 3 Inspect O ring 1 drive chain Damage Replace the drive chain Roller 2 Side plate 3 Damage wear Replace the drive chain 4 Measu...

Page 99: ...When installing the drive chain apply the lith ium soap base grease on the joint and O rings 7 Install Link plate 4 NOTE Press the link plate onto the joint using a chain riveter 5 Rivet the end of the joint using a chain riv eter After riveting the joint make sure its move ment is smooth New New 8 Lubricate Drive chain Drive chain lubricant SAE 10W 30 motor oil or suit able chain lubricants ...

Page 100: ...n position Drive chain slack 40 50 mm 1 6 2 0 in 3 Adjust Drive chain slack Drive chain slack adjustment steps Loosen the axle nut 1 and locknuts 2 Adjust the chain slack by turning the adjusters 3 To tighten Turn the adjuster 3 coun terclockwise To loosen Turn the adjuster 3 clock wise and push wheel for ward Turn each adjuster exactly the same amount to maintain correct axle alignment There are ...

Page 101: ...NSPECTION 1 Inspect Front fork smooth action Operate the front brake and stroke the front fork Unsmooth action oil leakage Repair or replace EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1 Remove Protector Dust seal 1 NOTE Use a thin screw driver and be careful not to damage the inner fork tube and dust seal 2 Clean Dust seal a Oil seal b NOTE Clean the dust seal and oil seal after every run...

Page 102: ...nder the engine 2 Remove the air bleed screw 1 and release the internal pressure from the front fork 3 Install Air bleed screw T R 1 Nm 0 1 m kg 0 7 ft lb EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust Rebound damping force By turning the adjuster 1 Stiffer a Increase the rebound damp ing force Turn the adjuster 1 in Softer b Decrease the rebound damp ing force Turn the adjuster 1 o...

Page 103: ...s adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Standard position 10 clicks out 8 clicks out EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1 Remove Rubber cap 2 Adjust Compression damping force By turning the adjuster 1 Stiffer a Increase the compression damping force Turn the adjuster 1 in Softer b Decrease the compression da...

Page 104: ... maximum extent of adjustment The adjuster may be damaged WARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install Rubber cap Standard position 13 clicks out EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect Swingarm smooth action Abnormal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage...

Page 105: ...t and adjuster before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten Locknut 6 Install Rear frame upper Rear frame lower Stiffer Increase the spring preload Turn the adjuster 2 in Softer Decrease the spring preload Turn the adjuster 2 out Spring length installed...

Page 106: ...Fully turned in position 20 clicks out from maximum 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 mark a on the adjuster with the punch mark b on the bracket For EUROPE AUS NZ and ZA CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged ...

Page 107: ...urn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum 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 mark a on the adjuster with the punch mark b on the high compression damping adjuster For EUROPE AUS NZ and ZA CAUTION Do not force the ...

Page 108: ...m Minimum Fully turned in position 2 turns out from maximum position STANDARD POSITION This is the position which is back by the spe cific number of turns from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the adjuster body For EUROPE AUS NZ and ZA CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster ma...

Page 109: ...its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position Standard tire pressure 100 kPa 1 0 kgf cm2 15 psi EC36S002 SPOKES INSPECTION AND TIGHTENING 1 Inspect Spokes 1 Bend damage Replace Loose spoke Retighten 2 Tighten Spokes NOTE Be sure to retighten these spokes before and after break in After a practice or ...

Page 110: ...g shaft Grasp the bottom of the forks and gen tly rock the fork assembly back and forth Free play Adjust steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps Remove the headlight Remove the handlebar and handle crown Loosen the ring nut 1 using the ring nut wrench 2 Ring n...

Page 111: ...ve the steering shaft assembly and inspect the steering bearings Install the plain washer 5 handle crown 6 plain washer 7 steering shaft nut 8 steering shaft cap 9 handlebar 0 han dlebar holder A and headlight B NOTE The handlebar holder should be installed with the punched mark a forward Insert the end of the fuel breather hose C into the hole in the steering shaft cap CAUTION First tighten the b...

Page 112: ...5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 0 Hot starter cable end Å Use Yamaha cable lube or equivalent on these areas ı Use SAE 10W 30 motor oil or suitable chain lubricants Ç Lubricate the following areas with high quality lightweight lithium soap base grease CAUTION Wipe off any excess grease and avoid get ting greas...

Page 113: ... many hours at low speeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of specification Regap Spark plug gap 0 7 0 8 mm 0 028 0 031 in 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten Spark plug NOTE Before installing a spark plug clean the gas ket surface a...

Page 114: ...M 33277 A 90890 03141 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Checking steps Start the engine and let it warm up Let the engine run at the specified speed Adjust the engine idling speed Refer to IDLE SPEED ADJUSTMENT section Visually check the stationary pointer a is within the firing range b on the rotor Incorrect firing range Check rotor and pickup assembly 1 4 Install Timin...

Page 115: ...d bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION Charging time charging am...

Page 116: ...tery terminals CAUTION First disconnect the negative battery lead 1 and then the positive battery lead 2 3 Remove Battery band Battery 4 Measure Battery charge Measurement steps Connect a pocket tester 1 to the battery terminals Tester positive probe battery positive terminal Tester negative probe battery negative terminal NOTE The charge state of an MF battery can be checked by measuring its open...

Page 117: ...t use a high rate battery charger since it forces a high amperage current into the battery quickly and can cause battery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the machine If charging has to be done with the battery mounted on the mach...

Page 118: ...d clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has b...

Page 119: ...3 54 INSP ADJ BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger ...

Page 120: ...3 55 INSP ADJ BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger ...

Page 121: ...y terminal 10 Install Seat EAS00181 FUSE INSPECTION CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Seat Fuse cover 2 Check Continuity 2 Reserve fuse Recommended lubricant Lithium soap base grease Checking steps Remove the fuse 1 Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 Po...

Page 122: ...e main switch to OFF Install a new fuse of the correct amperage Set on the switches to verify if the electri cal circuit is operational If the fuse immediately blows again check the electrical circuit Items Amperage rating Q ty Main fuse 10 A 1 REPLACING THE HEADLIGHT BULBS 1 Remove Headlight Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAP TER 4 2 Remove Headlight bulb holder cover 1 3...

Page 123: ...rsely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Attach Headlight bulb holder 7 Install Headlight bulb holder cover 8 Install Headlight Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAP TER 4 New T R 7 Nm 0 7 m kg 5 1 ft lb ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically Adjusting steps Turn the...

Page 124: ...t name Q ty Remarks Preparation for removal SEAT FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Fitting band 1 Remove on fuel tank side 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 Refer to REMOVAL POINTS 7 Side cover right 1 8 Headlight coupler 1 9 Headlight 1 1 3 2 3 4 SEAT FUEL TANK AND SIDE COVERS ...

Page 125: ... POINTS Side cover 1 Remove Bolt side cover Side cover left 1 Side cover right 2 NOTE Draw the side cover downward to remove it because its claws a are inserted in the air fil ter case SEAT FUEL TANK AND SIDE COVERS 4 ...

Page 126: ...moval Extent of removal Order Part name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Side cover right Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Silencer 1 5 Clamp 1 6 Nut exhaust pipe 1 7 Bolt exhaust pipe 1 8 Exhaust pipe 1 9 Gasket 2 2 1 2 ...

Page 127: ...E First temporarily tighten the nut exhaust pipe then tighten the bolt exhaust pipe 20 Nm 2 0 m kg 14 ft lb After that retighten the nut exhaust pipe 13 Nm 1 3 m kg 9 4 ft lb and then the bolt exhaust pipe 24 Nm 2 4 m kg 17 ft lb 3 1 2 New T R 13 Nm 1 3 m kg 9 4 ft lb T R 24 Nm 2 4 m kg 17 ft lb 2 Install Clamp 1 Gasket 2 Silencer 3 Washer 4 Bolt silencer 5 2 New 1 3 4 4 5 T R 20 Nm 2 0 m kg 14 ft...

Page 128: ...NT REPLACEMENT section in the CHAPTER 3 Seat fuel tank and side cover Refer to SEAT FUEL TANK AND SIDE COVERS section Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section 1 Engine guard 1 2 Panel 2 3 Clamp 8 4 Radiator right 1 5 Hose 2 1 6 Hose 3 1 7 Hose 4 1 8 Pipe 2 O ring 1 1 9 Radiator breather hose 1 10 Radiator left 1 11 Hose 1 1 12 Pipe 1 O ring 1 1 13 Coolant reservoir hose 1 14 Coolant...

Page 129: ...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 com pressed air through rear of the radiator Bent fin Repair replace EC455000 ASSEMBLY AND INSTALLATION Radiator 1 Install Pipe 1 1 Hose 1 2 Pipe 2 3 Hose 3 4 Hose 4 5 2 Install H...

Page 130: ...hose 1 Radiator right 2 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install Panel 1 Bolt radiator panel upper 2 NOTE Fit the hook a on the inner side first into the radiator T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 131: ...val 1 Carburetor removal Extent of removal Order Part name Q ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Clamp 1 2 Band 1 3 TPS coupler 1 4 Throttle cable cover 1 5 Throttle cable 2 6 Clamp air cleaner joint 1 Loosen the screw air cleaner joint 7 Clamp carburetor joint 2 Loosen the screws carburetor joint 8 Hot starter plunger 1...

Page 132: ...LY 1 Breather hose 4 2 Valve lever housing cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 0 Air cut valve cover 1 A Spring air cut valve 1 B Diaphragm air cut valve 1 C Float chamber 1 D Leak jet 1 E Pilot screw 1 Refer to REMOVAL POINTS F Float pin 1 G Float 1 1 ...

Page 133: ...Part name Q ty Remarks H Needle valve 1 I Main jet 1 J Needle jet 1 K Spacer 1 L Pilot jet 1 M Starter jet 1 N Push rod 1 Pull the push rod O Throttle shaft assembly 1 P Push rod link lever assembly 1 Q Pilot air jet 1 R Cold starter plunger 1 1 ...

Page 134: ...ally set at the factory Before removing the pilot screw turn it in fully and count the number of turns Record this number as the factory set number of turns out INSPECTION Carburetor 1 Inspect Carburetor body Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire 2 Inspect Main jet 1 Pilot jet 2 Needle jet 3 Starter ...

Page 135: ...k Repair or replace Insert the throttle valve 1 into the car buretor body and check for free move ment EC464400 Jet needle 1 Inspect Jet needle 1 Bends wear Replace Clip groove Free play exists wear Replace Clip position Standard clip position No 4 Groove EC464511 Float height 1 Measure Float height a Out of specification Adjust Float height 8 0 mm 0 31 in ...

Page 136: ...istance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE The float arm should be resting on the nee dle valve but not compressing the needle valve If the float height is not within specifica tion 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 flo...

Page 137: ...nspect Throttle shaft 1 Spring 2 Lever 1 3 Spring 1 4 Lever 2 5 Spring 2 6 Dirt Clean 1 2 3 4 5 6 Air cut valve 1 Inspect Diaphragm air cut valve 1 Spring air cut valve 2 Air cut valve cover 3 O ring 4 Tears diaphragm damage Replace 1 2 3 4 ASSEMBLY AND INSTALLATION Carburetor 1 Install Cold starter plunger 1 2 Install Pilot air jet 1 1 CARBURETOR ...

Page 138: ...nstall Spring 2 1 To lever 2 2 1 2 5 Install Push rod link lever assembly 1 NOTE Make sure the stopper a of the spring 2 fits into the recess b in the carburetor 1 a b 6 Install Plain washer 1 Circlip 2 2 1 7 Install Spring 1 To throttle shaft 2 NOTE Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley ...

Page 139: ...sition sensor Make sure the stopper c of the spring fits into the recess in the carburetor Turn the throttle shaft assembly left while holding down the lever 1 5 and fit the throt tle stop screw tip d to the stopper e of the throttle shaft assembly pulley 1 2 3 4 b a c e d 5 9 Install Push rod 1 NOTE While holding down the lever 1 2 insert the push rod farthest into the carburetor 1 2 10 Install S...

Page 140: ...ion points Turn in the pilot screw until it is lightly seated Turn out the pilot screw by the number of turns recorded before removing Pilot screw 1 3 4 turns out example 1 1 2 turns out example 13 Install O ring Leak jet 1 Float chamber 2 Screw float chamber 3 Cable holder throttle stop screw cable 4 Hose holder carburetor breather hose 5 5 3 2 4 5 1 14 Install Diaphragm air cut valve 1 Spring ai...

Page 141: ...Jet needle 1 Collar 2 Spring 3 Needle holder 4 Throttle valve plate 5 To throttle valve 6 5 6 1 2 3 4 17 Install Throttle valve assembly 1 Screw throttle shaft 2 NOTE Install the valve lever rollers 3 into the slits a of the throttle valve 18 Install O ring 1 Valve lever housing cover 2 Bolt valve lever housing cover 3 19 Install Carburetor breather hose 1 Refer to CABLE ROUTING DIA GRAM section i...

Page 142: ...erator pump adjust ing screw 3 Check that the link lever 4 has free play b by pushing lightly on it Gradually turn out the adjusting screw while moving the link lever until it has no more free play Carburetor installation 1 Install Carburetor joint 1 NOTE Install the projection a on the cylinder head between the carburetor joint slots b T R 3 Nm 0 3 m kg 2 2 ft lb 2 Install Carburetor 1 NOTE Insta...

Page 143: ...Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 2 1 T R 4 Nm 0 4 m kg 2 9 ft lb T R 11 Nm 1 1 m kg 8 0 ft lb 7 Install Throttle cable cover 1 Screw throttle cable cover 2 2 1 T R 4 Nm 0 4 m kg 2 9 ft lb 8 Install TPS throttle position sensor coupler 1 Clamp 2 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 9 Install Clamp 1 Refer to CABLE ROUTING DIA GRAM section in the CHAPT...

Page 144: ...EMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section 1 Spark plug 1 2 Engine upper bracket right 1 3 Engine upper bracket left 1 4 Cylinder head breather hose 1 5 Oil tank breather hose 1 6 Bolt cylinder head cover 2 7 Cylinder head cover 1 8 Gasket 1 9 Timing chain guide upper 1 1 ...

Page 145: ...nt of removal Order Part name Q ty Remarks CAMSHAFTS REMOVAL 1 Timing plug 1 Refer to REMOVAL POINTS 2 Straight plug 1 3 Tensioner cap bolt 1 4 Timing chain tensioner 1 5 Gasket 1 6 Bolt camshaft cap 10 7 Camshaft cap 2 8 Clip 2 9 Exhaust camshaft 1 10 Intake camshaft 1 1 ...

Page 146: ...at the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface as shown in the illustration If there is no clearance rotate the crank shaft counterclockwise one turn 1 2 b a 3 Loosen Tensioner cap bolt 1 4 Remove Timing chain tensioner 2 5 Remove Bolt camshaft cap 1 Camshaft caps 2 NOTE Remove the b...

Page 147: ...ace 2 Measure Cam lobes length a and b Out of specification Replace Cam lobes length Intake a 31 200 31 300 mm 1 2283 1 2323 in Limit 31 100 mm 1 2244 in b 22 550 22 650 mm 0 8878 0 8917 in Limit 22 450 mm 0 8839 in Exhaust a 30 950 31 050 mm 1 2185 1 2224 in Limit 30 850 mm 1 2146 in b 22 494 22 594 mm 0 8856 0 8895 in Limit 22 394 mm 0 8817 in 3 Measure Runout camshaft Out of specification Repla...

Page 148: ...0 Nm 1 0 m kg 7 2 ft lb NOTE Tighten the bolts camshaft cap in a criss cross pattern from innermost to outer caps Do not turn the camshaft when measuring clearance with the Plastigauge Remove the camshaft caps and measure the width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace cam shaft case and camshaft caps as a ...

Page 149: ...e tensioner rod up fully clockwise When releasing the screwdriver by pressing lightly with fingers make sure that the tensioner rod will come out smoothly If not replace the tensioner assembly ASSEMBLY AND INSTALLATION 1 Install Exhaust camshaft 1 Intake camshaft 2 Installation steps Turn the crankshaft counterclockwise until the I mark a on the rotor is aligned with the stationary pointer b on th...

Page 150: ...Damage or improper valve timing will result Install the clips and camshaft caps 4 T R Bolt camshaft cap 10 Nm 1 0 m kg 7 2 ft lb NOTE Apply the engine oil on the thread and con tact surface of the bolts camshaft cap 5 Tighten the bolts camshaft cap in a criss cross pattern CAUTION The bolts camshaft cap must be tight ened evenly or damage to the cylinder head camshaft caps and camshaft will result...

Page 151: ... Nm 1 0 m kg 7 2 ft lb Release the screwdriver check the ten sioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the speci fied torque T R Tensioner cap bolt 7 Nm 0 7 m kg 5 1 ft lb 5 4 New 3 Turn Crankshaft Counterclockwise several turns 4 Check Rotor I mark Align with the crankcase stationary pointer Camshaft match marks Align with the cylinder head surface Out of alignment Adj...

Page 152: ...ch the specified angle 180 in the proper tightening sequence Extent of removal Order Part name Q ty Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Radiator Refer to RADIATOR section Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHAFTS section ...

Page 153: ...ead warpage Out of specification Resurface Cylinder head warpage Less than 0 05 mm 0 002 in Warpage measurement and resurface ment steps Place a straightedge and a feeler gauge across the cylinder head Use a feeler gauge to measure the warpage If the warpage is out of specification resurface the cylinder head Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a fi...

Page 154: ... the rota tion angle procedure to obtain uniform tightening torque Wash the threads and contact surfaces of the bolts the contact surfaces of the plain washers the contact surface of the cylin der head and the threads of the crank case Apply the molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the plain washers Install the plain washers a...

Page 155: ...er head 2nd 20 Nm 2 0 m kg 14 ft lb Put a mark on the corner 1 of the bolt cylinder head and the cylinder head 2 as shown NOTE Tighten the bolts 90 in each of the two steps to reach the specified angle of 180 in the proper tightening sequence as shown T R Bolts cylinder head Final Specified angle 180 1 2 180 3 Install Nut cylinder head 1 T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install Copper washer 1 Oil d...

Page 156: ...l Order Part name Q ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Use special tool Refer to REMOVAL POINTS 2 Adjusting pad 5 3 Valve cotter 10 4 Valve retainer 5 5 Valve spring 5 6 Stem seal 5 7 Valve spring seat 5 8 Exhaust valve 2 9 Intake valve 3 1 ...

Page 157: ...akage at the valve seat Inspect the valve face valve seat and valve seat width Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that the valve seals properly There should be no leakage at the valve seat 2 3 Remove Valve cotters NOTE Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters Valve spring compre...

Page 158: ...03 in Exhaust 0 020 0 047 mm 0 0008 0 0019 in Limit 0 10 mm 0 004 in 2 Replace Valve guide Replacement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head in an over to 100 C 212 F Remove the valve guide using a valve guide remover 1 Install the new valve guide using a valve guide remover 1 and valve guide installer 2 After installing the valve guide bo...

Page 159: ...ake 4 5 mm 0 18 in YM 4118 90890 04118 Exhaust 5 0 mm 0 20 in YM 4099 90890 04099 NOTE After replacing the valve guide reface the valve seat 3 Inspect Valve face Pitting wear Grind the face Valve stem end Mushroom shape or diameter larger than the body of the stem Replace 4 Measure Margin thickness a Out of specification Replace Margin thickness Intake 1 0 mm 0 039 in Limit 0 85 mm 0 033 in Exhaus...

Page 160: ...h a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps Apply Mechanic s blueing dye Dykem b to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern Measure the valve...

Page 161: ...alve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping compound to the valve face and repeat the above steps NOTE After every lapping operation be sure to clean off all of the compound from the valve face and valve seat Apply Mechanic s blueing dye Dyke...

Page 162: ...8 in Exhaust 37 68 mm 1 48 in Limit 35 79 mm 1 41 in Compressed spring force Intake 111 3 127 9 N at 27 87 mm 11 3 13 0 kg at 27 87 mm 24 91 28 66 lb at 1 10 in Exhaust 127 4 146 4 N at 27 38 mm 13 0 14 9 kg at 27 38 mm 28 66 32 85 lb at 1 08 in 3 Measure Spring tilt a Out of specification Replace Spring tilt limit Intake 2 5 1 61 mm 0 063 in Exhaust 2 5 1 65 mm 0 065 in Valve lifter 1 Inspect Val...

Page 163: ...Cylinder head mark a color Valve lifter mark b color Blue Blue Yellow Yellow Purple Black a b ASSEMBLY AND INSTALLATION 1 Apply Molybdenum disulfide oil Onto the valve stem and valve stem seal 2 Install Valves 1 Valve spring seats 2 Valve stem seals 3 Valve springs 4 Valve spring retainers 5 NOTE Make sure that each valve is installed in its original place also referring to the painted color as fo...

Page 164: ... valve tip with a piece of wood CAUTION Hitting the valve tip with excessive force could damage the valve Valve spring compressor YM 4019 90890 04019 5 Install Adjusting pad 1 Valve lifter 2 NOTE Apply the engine oil on the valve lifters Apply the molybdenum disulfide oil on the valve stem end Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads...

Page 165: ...nt of removal Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Gasket 1 4 Dowel pin 2 5 Dowel pin O ring 1 1 6 Piston pin clip 2 Use special tool Refer to REMOVAL POINTS 7 Piston pin 1 8 Piston 1 9 Piston ring set 1 2 1 ...

Page 166: ...to drive the piston pin out Piston ring 1 Remove Piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration INSPECTION Cylinder and piston 1 Inspect Cylinder and piston walls Vertical scratches Replace cylinder and piston 2 Measure Piston to cylinder clearance Piston pin puller YU 1304 90890 01304 Measure...

Page 167: ...ure the piston skirt diameter P with a micrometer a 8 mm 0 315 in from the piston bottom edge Piston size P Standard 94 945 94 960 mm 3 738 3 739 in If out of specification replace the piston and piston rings as a set 3rd step Calculate the piston to cylinder clearance with following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 040 0 0...

Page 168: ...n crown so that the ring will be at a right angle to the cylinder bore a 10 mm 0 39 in Side clearance Standard Limit Top ring 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in 3 Measure Ring end gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of the oil control ring If the oil control ring rails sh...

Page 169: ...and piston rings liberally with engine oil Measurement steps Measure the outside diameter piston pin a If out of specification replace the piston pin Outside diameter piston pin 17 991 18 000 mm 0 7083 0 7087 in Measure the inside diameter piston b Inside diameter piston 18 004 18 015 mm 0 7088 0 7093 in Calculate the piston pin to piston clear ance with the following formula Piston pin to piston ...

Page 170: ...cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase Install the piston pin clips with their ends fac ing downward 4 Lubricate Piston Piston rings Cylinder NOTE Apply a liberal coating of engine oil Cylinder 1 Install Dowel pins O ring Gasket 1 Cylinder 2 NOTE Install the cylinder with one hand while com pressing the piston rings with the other hand C...

Page 171: ...er Part name Q ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Gasket 1 3 Dowel pin 2 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Plain washer 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 4 1 2 3 1 ...

Page 172: ... of removal Order Part name Q ty Remarks 12 Clutch plate 8 13 Friction plate 9 14 Nut 1 Use special tool Refer to REMOVAL POINTS 15 Look washer 1 16 Clutch boss 1 17 Thrust washer 1 18 Clutch housing 1 19 Push lever 1 4 1 3 ...

Page 173: ...91042 90890 04086 Å ı EC494000 INSPECTION EC484100 Clutch housing and boss 1 Inspect Clutch housing 1 Cracks wear damage Replace Clutch boss 2 Scoring wear damage Replace EC484201 Primary driven gear 1 Check Circumferential play Free play exists Replace Gear teeth a Wear damage Replace EC484400 Clutch spring 1 Measure Clutch spring free length a Out of specification Replace springs as a set Clutch...

Page 174: ...re Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Limit 2 8 mm 0 110 in Warp limit 0 1 mm 0 004 in Push lever 1 Inspect Push lever 1 Wear damage Replace EC484810 Push rod 1 Inspect Push rod 1 1 Bearing 2 Plain washer 3 Push rod 2 4 Ball 5 Wear damage bend Replace ...

Page 175: ...he push lever and tighten the bolt seat plate 2 1 a T R 10 Nm 1 0 m kg 7 2 ft lb Clutch 1 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 NOTE Apply the engine oil on the primary driven gear inner circumference 2 Install Lock washer 1 Nut clutch boss 2 NOTE Use the clutch holding tool 3 to hold the clutch boss Å For USA and CDN ı Except for USA and CDN Clutch holding tool YM 91042 9089...

Page 176: ...tarting with a friction plate and ending with a friction plate Apply the engine oil on the friction plates and clutch plates 5 Install Bearing 1 Plain washer 2 Circlip 3 To push rod 1 4 NOTE Apply the engine oil on the bearing and plain washer New 6 Install Push rod 2 1 Ball 2 Push rod 1 3 NOTE Apply the engine oil on the push rod 1 2 and ball 7 Install Pressure plate 1 ...

Page 177: ...E Tighten the bolts in stage using a crisscross pattern T R 8 Nm 0 8 m kg 5 8 ft lb 9 Install Gasket clutch cover 1 Dowel pin 2 New 10 Install Clutch cover 1 Bolt clutch cover NOTE Tighten the bolts in stage using a crisscross pattern T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 178: ...emarks OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drain the coolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake pedal Refer to ENGINE REMOVAL section Clutch cover Refer to CLUTCH section 1 Oil filter cover 1 2 Oil...

Page 179: ...ent of removal Order Part name Q ty Remarks 7 Oil hose 1 8 Kickstarter 1 9 Crankcase cover right 1 10 Gasket 1 11 Dowel pin O ring 4 2 12 Impeller 1 Refer to REMOVAL POINTS 13 Plain washer 1 14 Impeller shaft 1 15 Oil seal 1 1 16 Oil seal 2 1 17 Bearing 1 2 3 2 ...

Page 180: ...cross the flats a with spanners etc and remove the impeller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discolora tion of coolant or milky transmission oil 1 Remove Bearing 1 Oil seal 2 INSPECTION EC444200 Impeller shaft 1 Inspect Impeller shaft 1 Bend wear damage Replace Fur deposits Clean ...

Page 181: ...e EC444400 Oil seal 1 Inspect Oil seal Wear damage Replace ASSEMBLY AND INSTALLATION EC4G5110 Oil seal 1 Install Oil seal 1 NOTE Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing inward Bearing 1 Install Bearing 1 NOTE Install the bearing by pressing its outer race parallel New ...

Page 182: ...nd install the shaft while turning it Hold the impeller shaft on its width across the flats a with spanners etc and install the impeller T R 14 Nm 1 4 m kg 10 ft lb Crankcase cover right 1 Install Dowel pin 1 O ring 2 Collar 3 Gasket 4 New 2 Install Crankcase cover right 1 Bolt NOTE Apply the engine oil on the impeller shaft end When installing the crankcase cover onto the crankcase be sure that t...

Page 183: ...distance a between the kickstarter and the fuel tank is 12 mm 0 47 in or more T R 33 Nm 3 3 m kg 24 ft lb 2 Install Oil hose 1 Bolt oil hose 2 T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install Copper washer 1 Oil delivery pipe 2 Union bolt M8 3 Union bolt M10 4 New T R 18 Nm 1 8 m kg 13 ft lb T R 20 Nm 2 0 m kg 14 ft lb Water pump housing 1 Install Dowel pin 1 O ring 2 New ...

Page 184: ...housing 2 Plain washer 3 Coolant drain bolt 4 T R 10 Nm 1 0 m kg 7 2 ft lb New T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install O ring Coolant pipe 1 Bolt coolant pipe 2 T R 10 Nm 1 0 m kg 7 2 ft lb Oil filter 1 Install Oil filter 1 O ring 2 Oil filter cover 3 Bolt oil filter cover New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 185: ...using Refer to CLUTCH section Crankcase cover right Refer to OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT section Stator Refer to AC MAGNETO AND STARTER CLUTCH section 1 Nut primary drive gear 1 Refer to REMOVAL POINTS 2 Nut balancer 1 3 Lock washer 1 4 Primary drive gear 1 5 Balancer drive gear 1 6 Lock washer 1 7 Balancer driven gear 1 8 Balancer 1 Refer to REMOVAL POINTS 2 1 2 ...

Page 186: ...ar 3 and driven gear 4 Balancer 1 Remove Balancer 1 NOTE When removing the balancer shaft align the center of the balancer shaft weight a along the line connecting the centers of the crank shaft and balancer shaft INSPECTION Primary drive gear balancer drive gear and balancer driven gear 1 Inspect Primary drive gear 1 Balancer drive gear 2 Balancer driven gear 3 Wear damage Replace Balancer 1 Insp...

Page 187: ...en gear with the lower spline b on the balancer end 3 Install Balancer drive gear 1 NOTE Align the punched mark a on the balancer drive gear with the punched mark b on the balancer driven gear Align the punched mark c on the balancer drive gear with the lower spline d on the crankshaft 4 Install Lock washer 1 Nut balancer 2 Primary drive gear 3 Nut primary drive gear 4 NOTE Install the primary dri...

Page 188: ...S ASSEMBLY Preparation for removal Clutch housing Refer to CLUTCH section Crankcase cover right Refer to OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT section 1 Circlip 1 2 Plate washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Dowel pin 1 6 Outer rotor 2 1 7 Circlip 1 8 Inner rotor 2 1 9 Pin 1 10 Oil pump cover 1 11 Outer rotor 1 1 12 Inner rotor 1 1 2 1 ...

Page 189: ...4 66 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 13 Pin 1 14 Washer 1 15 Oil pump drive shaft 1 16 Rotor housing 1 2 ...

Page 190: ... the oil pump Tip clearance a 0 12 mm or less 0 0047 in or less Limit 0 20 mm 0 008 in Tip clearance b 0 09 0 17 mm 0 0035 0 0067 in Limit 0 24 mm 0 009 in Side clearance c 0 03 0 10 mm 0 0012 0 0039 in Limit 0 17 mm 0 007 in 3 Check Unsmooth Repeat steps 1 and 2 or replace the defective parts ASSEMBLY AND INSTALLATION Oil pump 1 Install Oil pump drive shaft 1 Washer 2 Pin 3 Inner rotor 1 4 NOTE A...

Page 191: ...the pin into the groove in the inner rotor 2 4 Install Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt oil pump assembly L 30 mm 1 18 in 4 Bolt oil pump assembly L 25 mm 0 98 in 5 NOTE Apply the engine oil on the outer rotor 2 T R 2 Nm 0 2 m kg 1 4 ft lb New T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 5 Install Oil pump drive gear 1 Plate washer 2 Circlip 3 NOTE Apply the engine...

Page 192: ...moval Extent of removal Order Part name Q ty Remarks KICK AXLE AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to OIL PUMP section 1 Kick idle gear 1 2 Kick axle assembly 1 Refer to REMOVAL POINTS 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick axle 1 8 Plain washer 1 9 Shift pedal 1 10 Shift shaft 1 11 Collar 1 12 Torsion spring 1 3 2 1 4 1 ...

Page 193: ...r Part name Q ty Remarks 13 Roller 1 14 Shift guide 1 Refer to REMOVAL POINTS 15 Shift lever assembly 1 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to REMOVAL POINTS 4 ...

Page 194: ...embly is disassembled at the same time as the shift guide EC4N3100 Segment 1 Remove Bolt segment 1 Segment 2 NOTE Turn the segment counterclockwise until it stops and loosen the bolt INSPECTION EC4C4200 Kick axle and ratchet wheel 1 Check Ratchet wheel 1 smooth movement Unsmooth movement Replace Kick axle 2 Wear damage Replace Spring 3 Broken Replace EC4C4300 Kick gear kick idle gear and ratchet w...

Page 195: ...embly 1 Inspect Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EC4B4500 Stopper lever 1 Inspect Stopper lever 1 Wear damage Replace Torsion spring 2 Broken Replace EC4C5000 ASSEMBLY AND INSTALLATION Segment 1 Install Segment 1 Bolt segment NOTE Align the notch a on the segment with the pin b on the shift cam T R 30 Nm 3 0 m kg 22 ft lb ...

Page 196: ...nstall Spring 1 Pawl pin 2 Pawl 3 To shift lever 4 NOTE Apply the engine oil on the springs pawl pins and pawls 2 Install Shift lever assembly 1 To shift guide 2 T R 10 Nm 1 0 m kg 7 2 ft lb 2 1 3 Install Shift lever assembly 1 Shift guide 2 NOTE The shift lever assembly is installed at the same time as the shift guide Apply the engine oil on the bolt segment shaft 4 Install Bolt shift guide 1 T R...

Page 197: ...le assembly 1 Install Kick gear 1 Plain washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Plain washer 6 Circlip 7 To kick axle 8 NOTE Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel Align the punch mark a on the ratchet wheel with the punch mark b on the kick axle New New 2 Install Torsion spring 1 To kick axle 2 NOTE Make sure the stopper a of the tors...

Page 198: ... the kick axle stop per a and stopper plate 3 Apply the engine oil on the kick axle Slide the kick axle assembly into the crank case and make sure the kick axle stopper fits into the stopper plate 5 Hook Torsion spring 1 NOTE Turn the torsion spring clockwise and hook into the proper hole a in the crankcase Kick idle gear 1 Install Kick idle gear 1 Plain washer 2 Circlip 3 NOTE Install the kick id...

Page 199: ...s AC MAGNETO AND STATOR REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt radiator left Disconnect the AC magneto lead Refer to RADIATOR section 1 Shift pedal 1 2 Engine guard left 1 3 Cover idle gear 1 1 4 Idle gear 1 1 5 Bearing 1 6 Shaft 1 7 Crankcase cover left 1 ...

Page 200: ...kg 47 ft lb Extent of removal Order Part name Q ty Remarks 9 Dowel pin 2 10 Idle gear 2 1 11 Bearing 1 12 Shaft 1 13 Nut rotor 1 Refer to NOTE 14 Rotor 1 Use special tool Refer to REMOVAL POINTS 15 Woodruff key 1 16 Starter clutch 1 17 Starter clutch drive gear 1 18 Bearing 1 19 Plain washer 1 20 Holder 1 21 Pick up coil 1 22 Stator 1 3 2 1 3 ...

Page 201: ...tor 1 Use the rotor puller 2 Rotor puller YM 04141 90890 04141 EC4L4000 INSPECTION AC magneto 1 Inspect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace AC magneto and or stator EC4L4200 Woodruff key 1 Inspect Woodruff key 1 Damage Replace ...

Page 202: ...e starter clutch and the starter clutch drive gear should engage If the starter clutch drive gear and starter clutch do not engage the starter clutch is faulty and must be replaced When turning the starter clutch drive gear clockwise Å it should turn freely If the starter clutch drive gear does not turn freely the starter clutch is faulty and must be replaced EC4L5000 ASSEMBLY AND INSTALLATION AC ...

Page 203: ...90890 85505 T R 7 Nm 0 7 m kg 5 1 ft lb 3 Install Plain washer 1 Bearing 2 Starter clutch drive gear 3 Starter clutch 4 NOTE Apply the engine oil on the plain washer bear ing and starter clutch drive gear inner circum ference 4 Install Woodruff key 1 Rotor 2 NOTE Clean the tapered portions of the crankshaft and rotor When installing the woodruff key make sure that its flat surface a is in parallel...

Page 204: ...m 1 6 m kg 11 ft lb T R 65 Nm 6 5 m kg 47 ft lb 7 Install Dowel pin Gasket crankcase cover left Crankcase cover left 1 Bolt crankcase cover left NOTE Tighten the bolts in stage using a crisscross pattern New T R 10 Nm 1 0 m kg 7 2 ft lb 8 Install Shaft 1 Bearing 2 Idle gear 1 3 NOTE Apply the engine oil on the shaft bearing and idle gear inner circumference 9 Install Cover idle gear 1 1 Bolt 2 NOT...

Page 205: ...Nm 2 3 m kg 17 ft lb 11 Connect AC magneto lead Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 12 Install Shift pedal 1 Bolt shift pedal NOTE When installing the shift pedal onto the shift shaft be sure that the center of the shift pedal is about 1 mm 0 04 in a above the top of the footrest T R 12 Nm 1 2 m kg 8 7 ft lb AC MAGNETO AND STARTER CLUTCH ...

Page 206: ...r to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable and guide Disconnect at the engine side Radiator Refer to RADIATOR section Shift pedal Refer to AC MAGNETO AND STARTER CLUTCH section Cylinder head breather ho...

Page 207: ...ing the starter motor lead Disconnect the starter motor lead Refer to ELECTRIC STARTING SYS TEM section in the CHAPTER 6 Negative battery lead Disconnect at the starter motor side 1 Engine skid plate front 1 2 Neutral switch 1 3 Oil hose 2 4 Chain cover 1 5 Nut drive sprocket 1 Refer to REMOVAL POINTS 6 Lock washer 1 7 Drive sprocket 1 8 Clip 1 9 Bolt brake pedal 1 10 Brake pedal 1 1 ...

Page 208: ...OVAL Extent of removal Order Part name Q ty Remarks 11 Engine upper bracket right 1 12 Engine upper bracket left 1 13 Engine lower bracket 2 14 Engine mounting bolt 3 15 Pivot shaft 1 Refer to REMOVAL POINTS 16 Engine 1 1 ...

Page 209: ... sprocket 1 Drive chain 2 NOTE Remove the drive sprocket together with the drive chain EC4M3301 Engine removal 1 Remove Pivot shaft 1 NOTE If the pivot shaft is pulled all the way out the swingarm will come loose If possible insert a shaft of similar diameter into the other side of the swingarm to support it 2 Remove Engine 1 From right side NOTE Make sure that the couplers hoses and cables are di...

Page 210: ...d plate front B Bolt engine skid plate C NOTE Apply the molybdenum disulfide grease on the pivot shaft T R 85 Nm 8 5 m kg 61 ft lb T R 69 Nm 6 9 m kg 50 ft lb T R 34 Nm 3 4 m kg 24 ft lb T R 69 Nm 6 9 m kg 50 ft lb T R 55 Nm 5 5 m kg 40 ft lb T R 55 Nm 5 5 m kg 40 ft lb T R 23 Nm 2 3 m kg 17 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb EC4M5211 Brake pedal 1 Install Spring Brake pedal 1 O ring 2 Bolt brake ...

Page 211: ...7 5 m kg 54 ft lb 3 Bend the lock washer tab to lock the nut 4 Install Chain guide Chain cover 1 Screw chain cover 2 5 Install O ring 1 Dowel pin 2 Oil hose 3 Bolt oil hose 4 NOTE Apply the lithium soap base grease on the O ring 6 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 NOTE Apply the lithium soap base grease on the O ring 2 1 T R 8 Nm 0 8 m kg 5 8 ft lb New T R 10 ...

Page 212: ... Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Balancer Refer to BALANCER section Kick axle assembly Refer to KICK AXLE AND SHIFT SHAFT section Segment Stator Refer to AC MAGNETO AND STARTER CLUTCH section 1 Timing chain guide rear 1 2 Timing chain 1 3 Bolt 50 mm 6 Refer to REMOVAL POINTS 4 Bolt 60 mm 3 5 Bolt 75 mm 3 6 Hose guide 1 7 Clutch cable holder 1 8 C...

Page 213: ...4 90 ENG CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q ty Remarks 10 Oil strainer 1 11 Oil delivery pipe 2 1 12 Crankshaft 1 Use special tool Refer to REMOVAL POINTS 2 ...

Page 214: ... 1 Crankcase bearing removal Extent of removal Order Part name Q ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Oil seal 3 2 Bearing 10 Refer to REMOVAL POINTS 1 ...

Page 215: ...tting slit a in the crankcase Lift the crankcase right horizontally while lightly patting the case splitting slit and engine mounting boss using a soft ham mer and leave the crankshaft and trans mission with the crankcase left CAUTION 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 halv...

Page 216: ...oved bearing Crankcase separating tool YU 1135 A 90890 01135 INSPECTION Timing chain and timing chain guide 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Inspect Timing chain guide Wear damage Replace EC4N4101 Crankcase 1 Inspect Contacting surface a Scratches Replace Engine mounting boss b crankcase Cracks damage Replace 2 Inspect Bearing Rotate inn...

Page 217: ...ge and stand YU 3097 90890 01252 Standard Limit Runout limit 0 03 mm 0 0012 in 0 05 mm 0 002 in Small end free play 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Side clearance 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Crack width 61 95 62 00 mm 2 439 2 441 in Oil strainer 1 Inspect Oil strainer Damage Replace Oil delivery pipe 1 Inspect Oil delivery pipe Cracks damage Replace Oil delivery pipe hol...

Page 218: ...sh the screw head periphery a into the concave b using a punch etc In so doing take care not to damage the screwdriver receiving hole in the screw head New T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb a b 1 T R 10 Nm 1 0 m kg 7 2 ft lb Crankshaft 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 and 5 Å For USA and CDN ı Except for USA and CDN Crankshaft installing pot 2...

Page 219: ...the crankshaft clean the contacting surface of crankcase CAUTION Do not use a hammer to drive in the crank shaft 2 Check Shifter operation Transmission operation Unsmooth operation Repair 3 Install Oil strainer 1 Bolt oil strainer 2 4 Apply Sealant On the crankcase right 1 NOTE Clean the contacting surface of crankcase left and right before applying the sealant Quick gasket ACC QUICK GS KT YAMAHA ...

Page 220: ...le holder Bolt crankcase NOTE Tighten the crankcase tightening bolts in stage using a crisscross pattern 7 Install Oil delivery pipe O ring Bolt oil delivery pipe 8 Install Timing chain Timing chain guide rear Bolt timing chain guide 9 Remove Sealant Forced out on the cylinder mating surface 10 Apply Engine oil To the crank pin bearing and oil deliv ery hole 11 Check Crankshaft and transmission op...

Page 221: ...and drive axle removal Extent of removal Order Part name Q ty Remarks TRANSMISSION SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Shift fork 1 1 Refer to REMOVAL POINTS 2 Shift fork 2 1 3 Shift fork 3 1 4 Shift cam 1 5 Main axle 1 6 Drive axle 1 7 Collar 1 1 ...

Page 222: ...r to remove Remove assembly carefully Note the posi tion of each part Pay particular attention to the location and direction of shift forks EC4H4000 INSPECTION EC4H4200 Gears 1 Inspect Matching dog a Gear teeth b Shift fork groove c Wear damage Replace 2 Inspect O ring 1 Damage Replace 3 Check Gears movement Unsmooth movement Repair or replace EC4H4600 Bearing 1 Inspect Bearing 1 Rotate inner race...

Page 223: ...malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork ASSEMBLY AND INSTALLATION Transmission 1 Install 5th pinion gear 25T 1 3rd pinion gear 16T 2 Collar 3 4th pinion gear 20T 4 2nd pinion gear 15T 5 To main axle 6 NOTE Apply the molybdenum disulfide oil on the 4th and 5th pinion gears inner circumference and on the end surface Apply th...

Page 224: ...the molybdenum disulfide oil on the 4th and 5th wheel gears inner circumfer ence Apply the lithium soap base grease on the O ring 3 Install Plain washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is positioned opposite side to the plain washer and gear b Be sure the circlip end c is positioned at axle spline groove d New 4 Install Collar 1 NOTE Apply the lithium soap base grease on ...

Page 225: ... oil on the shift fork grooves Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main axle 6 Install Transmission assembly 1 To crankcase left 2 NOTE Apply the engine oil on the bearings and guide bars 7 Check Shifter operation Transmission operation Unsmooth operation Repair ...

Page 226: ...r removal FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Trip meter cable 1 2 Hose cover 1 3 Bolt brake hose holder 2 Only loosening 4 Bolt axle holder 4 Only loosening 5 Nut front wheel axle 1 6 Front wheel axle 1 7 Front wheel 1 8 Trip meter gear unit 1 9 Collar 1 10 Oil seal 1 11...

Page 227: ... REMOVAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Chain puller 2 4 Rear wheel 1 Refer to REMOVAL POINTS 5 Collar 2 6 Driven sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disc 1 2 3 1 3 FRONT WHEEL AND REAR WHEEL 5 ...

Page 228: ...f necessary 1 Remove Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set Wheel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in ...

Page 229: ... Wheel axle bending limit 0 5 mm 0 020 in EC594200 Brake disc 1 Measure Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc 2 Measure Brake disc thickness a Out of limit Replace Disc deflection limit Standard Limit Rear 0 15 mm 0 006 in Disc wear limit Standard Limit Front 3 0 mm 0 12 ...

Page 230: ...tward ACHTUNG CAUTION 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 NOTE Tighten the bolts in stage using a crisscross pattern New T R 12 Nm 1 2 m kg 8 7 ft lb 3 Install Collar 1 NOTE Apply the lithium soap base grease on the oil seal lip Install the collar with their projection a fac ing the wheel 4 Install Tri...

Page 231: ...etween the brake pads 2 correctly Make sure that the projections a in the trip meter gear unit fits over the stopper b on the front fork outer tube 6 Install Wheel axle 1 NOTE Apply the lithium soap base grease on the wheel axle 7 Install Nut wheel axle 1 T R 105 Nm 10 5 m kg 75 ft lb ...

Page 232: ...lder 2 NOTE Before tightening the bolt brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into the hose groove d so that the brake hose does not contact the nut wheel axle 10 Install Hose cover 1 Plain washer 2 Bolt hose cover M8 3 Bolt hose cover M6 4 T R 10 Nm 1 0 m kg 7 2 ft lb T R 16 Nm 1 ...

Page 233: ...first Install the oil seal with its manufacture s marks or numbers facing outward ACHTUNG CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race New New 2 Install Brake disc 1 Bolt brake disc 2 NOTE Tighten the bolts in stage using a crisscross pattern T R 14 Nm 1 4 m kg 10 ft lb 3 Install Driven sprocket 1 Bolt driven sprocket 2 Plain washer driven spr...

Page 234: ...2 correctly 6 Install Drive chain 1 NOTE Push the wheel 2 forward and install the drive chain 7 Install Chain puller left 1 Wheel axle 2 NOTE Install the chain puller left and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 8 Install Chain puller right 1 Plain washer 2 Nut wheel axle 3 NOTE Temporarily tighten the nut wheel axle at this point ...

Page 235: ...slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAP TER 3 Drive chain slack 40 50 mm 1 6 2 0 in 10 Tighten Nut wheel axle 1 Locknut 2 T R 125 Nm 12 5 m kg 90 ft lb T R 16 Nm 1 6 m kg 11 ft lb FRONT WHEEL AND REAR WHEEL ...

Page 236: ... machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over Drain the brake fluid Refer to REMOVAL POINTS 1 Hose cover 1 2 Brake hose holder 1 3 Bolt brake hose holder 2 Only loosening 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the caliper 8 Caliper ...

Page 237: ...le stand under the engine WARNING Support the machine securely so there is no danger of it falling over Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to REMOVAL POINTS 1 Brake pedal 1 2 Master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the caliper 8 Cali...

Page 238: ...nt caliper disassembly 2 Rear caliper disassembly Extent of removal Order Part name Q ty Remarks CALIPER DISASSEMBLY A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Caliper piston 2 1 Refer to REMOVAL POINTS 5 Dust seal 2 1 6 Piston seal 2 1 1 2 FRONT BRAKE AND REAR BRAKE ...

Page 239: ...ront master cylinder disassembly 2 Rear master cylinder disassembly Extent of removal Order Part name Q ty Remarks MASTER CYLINDER DISAS SEMBLY 1 Master cylinder cap 1 2 Diaphragm 1 3 Master cylinder boot 1 4 Circlip 1 Use a long nose circlip pliers 5 Plain washer 1 6 Push rod 1 7 Master cylinder kit 1 1 2 1 2 ...

Page 240: ...ever in or pushing down on the pedal ACHTUNG CAUTION Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately EC533301 Caliper piston 1 Remove Caliper piston Use compressed air and proceed care fully WARNING Cover piston with rag and use extreme caution when expelling piston from cylin der Never attempt to pry out piston...

Page 241: ...n seals and dust seals whenever a caliper is disassembled Å Front ı Rear Å ı EC5A4000 INSPECTION EC534112 Master cylinder 1 Inspect Master cylinder inner surface a Wear scratches Replace master cyl inder assembly Stains Clean WARNING Use only new brake fluid Å Front ı Rear 2 Inspect Diaphragm 1 Crack damage Replace Å Front ı Rear ı Å ı Å 3 Inspect Master cylinder piston 1 Master cylinder cup 2 Wea...

Page 242: ...a caliper is disassembled EC534301 Brake hose 1 Inspect Brake hose 1 Crack damage Replace EC5A5000 ASSEMBLY AND INSTALLATION WARNING 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 EC5A5800 Caliper piston 1 Clean Caliper Piston seal Dust seal C...

Page 243: ...aliper piston 1 NOTE Apply the brake fluid on the piston wall ACHTUNG CAUTION Install the piston with its shallow depressed side a facing the caliper Never force to insert Å Front ı Rear EC5A5700 Front caliper 1 Install Pad support 1 Brake pad 2 Pad pin 3 NOTE Install the brake pads with their projections a into the caliper recesses b Temporarily tighten the pad pin at this point Å ı FRONT BRAKE A...

Page 244: ... 3 Install Brake hose holder 1 Caliper 2 Bolt caliper 3 NOTE Fit the brake hose holder cut a over the pro jection b on the front fork and clamp the brake hose 4 Tighten Pad pin 4 5 Install Pad pin plug 5 EC5A5100 Rear caliper 1 Install Pad support 1 Brake pad 2 Pad pin 3 NOTE Install the brake pads with their projections a into the caliper recesses b Temporarily tighten the pad pin at this point T...

Page 245: ...der kit 1 Clean Master cylinder Master cylinder kit Clean them with brake fluid T R 18 Nm 1 8 m kg 13 ft lb T R 3 Nm 0 3 m kg 2 2 ft lb 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 WARNING After installing cylinder cup should be installed as shown direction Wrong instal lation cause imprope...

Page 246: ...aster cylinder 5 NOTE Apply the brake fluid on the master cylinder kit Apply the lithium soap base grease on the tip of the push rod When installing the circlip use a long nose circlip pliers Å Front ı Rear EC5A5310 Front master cylinder 1 Install Master cylinder 1 Master cylinder bracket 2 Bolt master cylinder bracket 3 NOTE Install the bracket so that the arrow mark a face upward First tighten t...

Page 247: ...NG CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the master cylinder T R 6 Nm 0 6 m kg 4 3 ft lb T R 6 Nm 0 6 m kg 4 3 ft lb New T R 30 Nm 3 0 m kg 22 ft lb 2 Install Master cylinder 1 Bolt master cylinder 2 3 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 NOTE Apply the lithium soap base grease on the bolt O ...

Page 248: ...ake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into the hose groove d so that the brake hose does not contact the nut wheel axle T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install Hose cover 1 Plain washer 2 Bolt hose cover M8 3 Bolt hose cover M6 4 T R 16 Nm 1 6 m kg 11 ft lb T R 7 Nm 0 7 m kg 5 1 ft l...

Page 249: ...ts the master cylinder projection a and that its bent portion b faces downward New T R 30 Nm 3 0 m kg 22 ft lb Rear brake hose 1 Install Copper washer 1 Brake hose 2 Union bolt 3 WARNING Always use new copper washers ACHTUNG CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the caliper New T R 30 Nm 3 0 m kg 22 ft lb ...

Page 250: ... 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 chem ical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result ...

Page 251: ...der cap 1 Screw master cylinder cap 2 Rear Diaphragm Master cylinder cap 1 Bolt master cylinder cap 2 ACHTUNG CAUTION 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 Å Front ı Rear 5 Install rear brake only Protector 1 Bolt protector 2 Å T R...

Page 252: ...e WARNING Support the machine securely so there is no danger of it falling over Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front caliper Refer to FRONT BRAKE AND REAR BRAKE section Headlight Handlebar Refer to HANDLEBAR section 1 Protector 1 2 Brake hose holder 2 3 Pinch bolt handle crown 2 Only loosening 4 Cap bolt 1 Loosen when disassembling the front fork 5 Pinch bolt under bracket...

Page 253: ...Q ty Remarks FRONT FORK DISASSEMBLY 1 Cap bolt 1 Refer to REMOVAL POINTS 2 Fork spring 1 Drain the fork oil 3 Dust seal 1 Refer to REMOVAL POINTS 4 Stopper ring 1 5 Inner tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Plain washer 1 0 Oil seal 1 A Spring guide 1 B Base valve 1 Use special tool C Damper rod 1 Refer to REMOVAL POINTS 1 2 ...

Page 254: ... 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 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 EC553150 Cap bolt 1 Remove Cap bolt 1 From the outer tube NOTE Before removing the front fork from the machine l...

Page 255: ...uter tube EC553311 Damper rod 1 Remove Base valve 1 Damper rod 2 NOTE Use a damper rod holder 3 to lock the damper rod EC554000 INSPECTION EC554100 Damper rod 1 Inspect Damper rod 1 Bend damage Replace damper rod ACHTUNG CAUTION 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...

Page 256: ... grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube EC554600 Outer tube 1 Inspect Outer tube 1 Score marks wear damage Replace Fork spring free length Standard Limit 460...

Page 257: ...2 ACHTUNG CAUTION To install the damper rod 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 1 O ring 2 Base valve 3 To inner tube 4 4 Tighten Base valve 1 NOTE Use a damper rod holder 2 to lock the damper rod 3 Apply the LOCTITE on the base valve thread Damper rod holder YM 1423 90...

Page 258: ...al 1 Stopper ring 2 Oil seal 3 Plain washer 4 Slide metal 5 To inner tube 6 NOTE Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip Install the oil seal with its manufacture s marks or number facing the axle holder side New New 7 Install Piston metal 1 NOTE Install the piston metal onto the slot on inner tube New 8 I...

Page 259: ...ver 3 Fork seal driver YM 01442 90890 01442 10 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 Fork seal driver YM 01442 90890 01442 11 Install Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 12 Install Dust seal 1 NOTE Apply the lithium soap base grease on the inner tube ...

Page 260: ...ork performance Never allow foreign materials to enter the front fork Recommended oil Suspension oil 01 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distribute the fork oil 17 Fill Front fork oil Until outer tube top surface with recom mended fork oil once more 18 After filling pump the outer tube 1 slowly up and down about 200 mm 7 9 in stroke to distribute the ...

Page 261: ...with the fork oil up to the top of the outer tube and bleed the front forks 20 Measure Oil level left and right a Out of specification Adjust NOTE Be sure to install the spring guide 2 when checking the oil level WARNING Never fail to make the oil level adjustment between the maximum and minimum level and always adjust each front fork to the same setting Uneven adjustment can cause poor handling a...

Page 262: ...tion of the adjuster the amount of turning out the fully turned in posi tion 23 Install Cushion rubber 1 Washer 2 Spacer 3 To cap bolt 4 NOTE Install the cushion rubber with its smaller dia end a facing the cap bolt 24 Install Push rod 1 Fork spring 2 NOTE Install the fork spring with the damper rod 3 pulled up After installing the fork spring hold the damper rod end so that it will not go down 25...

Page 263: ...pecified torque 27 Install Cap bolt 1 To outer tube NOTE Temporarily tighten the cap bolt T R 29 Nm 2 9 m kg 21 ft lb 28 Install Protector guide 1 Installation 1 Install Front fork 1 NOTE Temporarily tighten the pinch bolts under bracket Do not tighten the pinch bolts handle crown yet 2 Tighten Cap bolt 1 3 Adjust Front fork top end a Front fork top end standard a Zero mm Zero in T R 30 Nm 3 0 m k...

Page 264: ...r 1 Bolt brake hose holder 2 Protector 3 Bolt protector 4 NOTE When installing the brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose 5 in front of the axle boss c and fit it into the hose groove d so that the brake hose does not contact the nut wheel axle T R 23 Nm 2 3 m kg 17 ft lb T R 20 Nm 2 0 m kg 14 ft lb T R 23 Nm 2 3 m kg 1...

Page 265: ...sconnect the clutch switch lead 5 ENGINE STOP button 1 Disconnect the ENGINE STOP button lead 6 Lights switch 1 7 Master cylinder 1 Refer to REMOVAL POINTS 8 Start switch 1 Disconnect the start switch lead 9 Throttle cable cap 1 10 Throttle cable 2 pushed 1 Disconnect at the throttle side 11 Throttle cable 1 pulled 1 Disconnect at the throttle side 12 Grip right 1 Refer to REMOVAL POINTS 13 Tube g...

Page 266: ... cylinder cap side hori zontal to prevent air from coming in EC5B3200 Grip 1 Remove Grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip which has become loose EC5B4000 INSPECTION EC5B4100 Handlebar 1 Inspect Handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar HANDLEBAR ...

Page 267: ...the handlebar 2 NOTE Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lacquer thinner Install the grip left to the handlebar so that the line b between the two arrow marks faces straight upward T R 28 Nm 2 8 m kg 20 ft lb 3 Install Grip right 1 Collar 2 Apply the adhesive on the tube guide 3 NOTE Before applying the adhesive wipe off grease or oil on the tube g...

Page 268: ...de 2 NOTE Apply the lithium soap base grease on the throttle cable end and tube guide cable wind ing portion 6 Install Throttle cable cap 1 Screw throttle cable cap 2 WARNING After tightening the screws check that the throttle grip 3 moves smoothly If it does not retighten the bolts for adjustment T R 4 Nm 0 4 m kg 2 9 ft lb 7 Install Cover grip cap 1 Cover throttle cable cap 2 ...

Page 269: ...bracket and then tighten the bolt on the lower side T R 9 Nm 0 9 m kg 6 5 ft lb Zero mm Zero in Zero mm Zero in 9 Install Lights switch 1 T R 2 Nm 0 2 m kg 1 4 ft lb 10 Install ENGINE STOP button 1 Clutch lever holder 2 Bolt clutch lever holder 3 Hot starter lever holder 4 Bolt hot starter lever holder 5 Clamp 6 NOTE The ENGINE STOP button clutch lever holder and clamp should be installed accord i...

Page 270: ...ble end 12 Adjust Clutch lever free play Refer to CLUTCH ADJUSTMENT section in the CHAPTER 3 Hot starter lever free play Refer to HOT STARTER LEVER ADJUSTMENT section in the CHAP TER 3 13 Fasten the hot starter cable 1 and clutch cable 2 with a clamp 3 1 2 3 14 Insert the end of the fuel breather hose 1 into the hole in the steering shaft cap 2 1 2 ...

Page 271: ...NDLEBAR section Preparation for removal Hold the machine by placing the suitable stand under the engine Headlight Handlebar Hose guide Front fender 1 Coupler bracket 1 2 Trip meter 1 3 Main switch 1 Disconnect the main switch lead 4 Steering shaft cap 1 5 Steering shaft nut 1 6 Front fork 2 Refer to FRONT FORK section 7 Handle crown 1 8 Ring nut 1 Use special tool Refer to REMOVAL POINTS 9 Under b...

Page 272: ...5 47 CHAS STEERING Extent of removal Order Part name Q ty Remarks 11 Bearing upper 1 12 Bearing lower 1 Refer to REMOVAL POINTS 13 Ball race 2 2 ...

Page 273: ...ing nut wrench YU 33975 90890 01403 EC563300 Bearing lower 1 Remove Bearing lower 1 Use the floor chisel 2 ACHTUNG CAUTION 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 STEERING ...

Page 274: ... their operation in the ball races replace bearings and ball races as a set EC565000 ASSEMBLY AND INSTALLATION 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 Ball race Bearing upper 1 Ball race cover 2 NOTE Apply the lithium soap base grease on the bearing and ball race cover lip 3 Install Under bracket...

Page 275: ...re is any binding remove the steering shaft assembly and inspect the steering bearings 6 Install Plain washer 1 7 Install Front fork 1 Handle crown 2 Main switch 3 Coupler bracket 4 Hose guide bracket 5 NOTE Install the coupler bracket on the outside of the hose guide bracket Temporarily tighten the pinch bolts under bracket Do not tighten the pinch bolts handle crown yet 8 Install Plain washer 1 ...

Page 276: ... a Front fork top end standard a Zero mm Zero in 12 Tighten Pinch bolt handle crown 1 Pinch bolt under bracket 2 ACHTUNG CAUTION Tighten the under bracket to specified torque If torqued too much it may cause the front fork to malfunction 13 Install Trip meter 1 Bolt trip meter 2 NOTE Install the trip meter over the coupler bracket 3 T R 23 Nm 2 3 m kg 17 ft lb T R 20 Nm 2 0 m kg 14 ft lb T R 7 Nm ...

Page 277: ... of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Brake hose holder Rear caliper Bolt brake pedal Drive chain Refer to FRONT BRAKE AND REAR BRAKE section Shift the brake pedal backward 1 Chain support 1 2 Chain tensioner lower 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 1 ...

Page 278: ...Connecting rod removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 8 Refer to REMOVAL POINTS 1 2 3 2 3 ...

Page 279: ... Replace EC574210 Relay arm 1 Inspect Bearing polylube bearing 1 Collar 2 Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect Bearing polylube bearing 1 Loss of solid lubrication Replace Oil seal 3 Damage Replace NOTE Polylube bearings with solid lubrication have been adopted with the intent to make the nee dle bearings used in this model maintenance free With p...

Page 280: ...e free With polylube bearings no grease nipple and regular lubrication is necessary However grease should be applied to all oil seals and collars when removed or installed EC575000 ASSEMBLY AND INSTALLATION EC575201 Bearing and oil seal 1 Install Bearing 1 Oil seal 2 To swingarm NOTE Apply the molybdenum disulfide grease on the bearing when installing Install the bearing by pressing it on the side...

Page 281: ... disulfide grease on the bearing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers Installed depth of bearings a 5 mm 0 20 in Installed depth of bearings a 5 mm 0 20 in Swingarm 1 Install Bush 1 Thrust bearing 2 Oil seal 3 Collar 4 To swingarm 5 NOTE Apply the molybdenum disulfide grease on the bushes thrust bearings and oil seal lips 2 Instal...

Page 282: ...b 5 Install Relay arm 1 Bolt relay arm 2 Plain washer 3 Nut relay arm 4 To swingarm NOTE Apply the molybdenum disulfide grease on the bolt Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 NOTE Apply the molybdenum disulfide grease on the pivot shaft Insert the pivot shaft from right side T R 85 Nm 8 5 m kg 61 ft lb 7 Check Swingarm side play a Free play exists Replace thrust bear ing ...

Page 283: ...nut yet 9 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt T R 53 Nm 5 3 m kg 38 ft lb 10 Tighten Nut connecting rod 1 T R 80 Nm 8 0 m kg 58 ft lb 11 Tighten Nut relay arm 1 T R 80 Nm 8 0 m kg 58 ft lb 12 Install Cap 1 NOTE Install the cap right with its mark a facing forward ...

Page 284: ...Chain tensioner 4 Nut chain tensioner lower 5 T R 20 Nm 2 0 m kg 14 ft lb 14 Install Chain support 1 Support cover 2 Bolt chain support r 50 mm 1 97 in 3 Nut chain support 4 Bolt support cover r 10 mm 0 39 in 5 T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb SWINGARM ...

Page 285: ...ger of it falling over Seat fitting band and side covers Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Air filter cover Refer to AIR FILTER CLEANING sec tion in the CHAPTER 3 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 Drain the coolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Coolant reservoir tank breather hose Disconnect at the coolant re...

Page 286: ...cking tie 2 2 Taillight coupler 1 3 Starting circuit cut off relay cou pler 1 4 Plastic band 2 5 Clamp air filter joint 1 Only loosening 6 Rear frame 1 7 Bolt rear shock absorber relay arm 1 Hold the swingarm 8 Bolt rear shock absorber frame 1 9 Rear shock absorber 1 10 Locknut 1 Only loosening 11 Adjuster 1 Only loosening 12 Spring guide lower 1 13 Spring guide upper 1 2 1 ...

Page 287: ...5 62 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ty Remarks 14 Spring rear shock absorber 1 15 Bearing 2 Refer to REMOVAL POINTS 2 ...

Page 288: ... damage 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 surface of the piston rod with the cylin der 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 abs...

Page 289: ...er bearing 1 NOTE Remove the bearing by pressing its outer race EC584000 INSPECTION Rear shock absorber 1 Inspect Damper rod 1 Bends damage Replace absorber assembly Shock absorber 2 Oil leaks Replace absorber assem bly Gas leaks Replace absorber assem bly Spring 3 Damage Replace spring Fatigue Replace spring Move spring up and down Spring guide 4 Wear damage Replace spring guide Bearing 5 Free pl...

Page 290: ...t will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install Stopper ring upper bearing 1 NOTE After installing the stopper ring push back the bearing until it contacts the stopper ring New 3 Install Lower bearing 1 NOTE Install the bearing by pressing it on the side having the manufacture s marks or numbers Installed depth of the bearing a 4 mm 0 16 in EC585111 Spri...

Page 291: ...ON Never attempt to turn the adjuster beyond the maximum or minimum setting 4 Tighten Locknut 1 Rear shock absorber 1 Install Dust seal 1 O ring 2 Collar 3 NOTE Apply the molybdenum disulfide grease on the bearing Apply the lithium soap base grease on the dust seals O rings and collars Spring length installed a Standard length Extent of adjustment 246 mm 9 69 in 246 5 mm 9 70 in 240 5 258 5 mm 9 4...

Page 292: ...ear shock absorber frame 1 Nut rear shock absorber frame 2 NOTE Apply the molybdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt T R 56 Nm 5 6 m kg 40 ft lb T R 53 Nm 5 3 m kg 38 ft lb 6 Install Rear frame 1 Bolt rear frame upper 2 Bolt rear frame lower 3 T R 32 Nm 3 2 m kg 23...

Page 293: ...5 68 CHAS 8 Install Plastic band 1 Starting circuit cut off relay coupler 2 Taillight coupler 3 Locking tie 4 3 2 1 4 REAR SHOCK ABSORBER ...

Page 294: ... Yellow B L Black Blue EC612000 WIRING DIAGRAM 1 23 45 6 78 9 0 A B C DEF GH I J K W R W R R B R B Br R B R B Br R W L R L B B B Sb L W W Y Y W L Y B B B W Y R Y W R L Y B Y L B L B B ON OFF 10A B B OFF ON OFF START START R Br L W B L Y Y L B L B B Br L W Br L W L B L B Y L B L B L W Sb B W B B B W R B W R B Gy Br L W ON STOP O B L Y Sb B L W R Br B W L B Gy W R B B O L Y Sb L R R W Y W Y W Y B B ...

Page 295: ...uter in the CDI unit as a throttle opening signal Pickup coil Detects signal rotor revolutions and inputs them into the computer in the CDI unit as engine revolution signals CDI unit The signals of the TPS and pickup coil sensor are analyzed by the computer in the CDI unit which then adjusts ignition timing for the operation requirements Principal of 3 Dimensional Control Conventionally ignition t...

Page 296: ...k Use the following special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 Pocket tester YU 3112 C 90890 03112 1 Check fuse Replace fuse and check wire harness 2 Check battery Recharge or replace Spark gap test 3 Clean or replace spark plug Check entire ignition system for connection couplers leads and ignition coil Repair or replace Check ENGINE STOP button Re...

Page 297: ... 0 mm 0 24 in Å ı COUPLERS LEADS AND IGNITION COIL CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace Ignition coil and spark plug as they are fitted Push in the ignition coil until it closely contacts the spark plug hole in the cyl inder head cover EC625001 ENGINE STOP BUTTON INSPECTION 1 Inspect ENGINE STOP button conduct No continuity...

Page 298: ... not come on Replace 3 Inspect Rubber part a Tears damage Replace Tester lead Red lead 1 Tester lead Brown lead 2 R 1 Br 2 Testerselector position ON Ω 1 OFF Battery lead Red Black lead 1 Battery lead Black lead 2 a EC626002 IGNITION COIL INSPECTION 1 Remove the ignition coil cap 2 Inspect Primary coil resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Black lead 2 Prima...

Page 299: ...er selector position 4 6 6 8 kΩ at 20 C 68 F kΩ 1 Tester lead Red lead 1 Tester lead White lead 2 Pick up coil resistance Tester selector position 248 372 Ω at 20 C 68 F Ω 100 R W 1 2 NEUTRAL SWITCH INSPECTION 1 Inspect Neutral switch conduct No continuity while in neutral Replace Continuity while in gear Replace EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found rep...

Page 300: ...ing when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above condi tions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 B...

Page 301: ...e 12 V battery in this inspection Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 1 Check fuse Replace fuse and check wire harness 2 Check battery Recharge or replace Check each coupler and wire connection Repair or replace 3 Check main switch Replace Check starter motor operation Repair or replace Check starting circuit cut off relay Replace Check starter re...

Page 302: ...jumper lead must have at least the same capacity or more as that of the battery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure nothing flammable is in the vicinity STARTING CIRCUIT CUT OFF RELAY INSPECTION 1 Remove Starting circuit cut off relay 2 Inspect Starting circuit cut off relay conduct Use 12 V battery Battery lead Blue Black lead 1 Batte...

Page 303: ...elay terminal 1 Battery lead Starter relay terminal 2 Tester lead Starter relay terminal 3 Tester lead Starter relay terminal 4 Ter minal 3 Ter minal 4 Tester selec tor position Connected to battery Ω 1 Not connected to battery CLUTCH SWITCH INSPECTION 1 Inspect Clutch switch continuity No continuous while being pulled Replace Continuous while being freed Replace Tester lead Black lead 1 Tester le...

Page 304: ...rminal 1 Tester Blue Yellow terminal 3 Continuous Tester Sky blue terminal 2 Tester Blue Red terminal 1 No continuous Tester Blue Yellow terminal 3 Tester Blue Red terminal 1 No continuous 2 3 1 START SWITCH INSPECTION 1 Inspect Start switch continuity No continuous while being pushed Replace Continuous while being freed Replace 2 Inspect Rubber part a Tears damage Replace Tester lead Black lead 1...

Page 305: ...Q ty Remarks STARTER MOTOR REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Crankcase cover left Refer to AC MAGNETO AND STARTER CLUTCH section in the CHAPTER 4 1 Starter motor 1 STARTER MOTOR DISASSEM BLY 1 Starter motor front cover 1 2 Washer starter motor front cover 1 3 Plain washer 1 4 Circlip 1 5 O ring 3 1 ...

Page 306: ...CTRIC STARTING SYSTEM 0 9 5 6 7 5 0 8 9 4 3 2 1 New New New B 5 1 Extent of removal Order Part name Q ty Remarks 6 Starter motor yoke 1 7 Armature assembly 1 8 Starter motor rear cover 1 9 Brush 2 0 Brush spring 2 1 ...

Page 307: ...NOTE The mica must be undercut to ensure proper operation of the commutator Min commutator diameter 16 6 mm 0 65 in Mica undercut 1 5 mm 0 06 in 4 Measure Armature assembly resistances com mutator and insulation Out of specification Replace the starter motor Measure the armature assembly resis tances with the pocket tester Pocket tester YU 03112 C 90890 03112 Armature assembly Commutator resistanc...

Page 308: ...in 6 Measure Brush spring force Out of specification Replace the brush springs as a set Brush spring force 3 92 5 88 N 400 600 gf 14 1 21 2 oz ASSEMBLY 1 Install Brush spring 1 Brush 2 2 Install Armature assembly 1 Install while holding down the brush using a thin screw driver CAUTION Be careful not to damage the brush during installation ...

Page 309: ...ing rear cover a b c 2 1 New New 4 Install O ring 1 Circlip Plain washer 2 Washer starter motor front cover 3 Starter motor front cover 4 NOTE For installation align the projections on the washer with the slots in the front cover Align the match mark a on the starter motor yoke with the match mark b on the starter motor front cover b a 4 3 2 1 New New 5 Install Bolt 1 O ring 2 NOTE Apply the lithi...

Page 310: ...g parts before inspection 1 Seat 2 Fuel tank Use the following special tool in this inspection Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 1 Check fuse Replace fuse and check wire harness 2 Check battery Recharge or replace Check each coupler and wire connection Repair or replace Check charging voltage Charging system is good Check AC magneto Ch...

Page 311: ...Out of specification If no failure is found in checking the source coil resis tance replace the rectifier regulator Tester lead Red lead 1 Tester lead Black lead 2 Charging voltage Tester selector position 14 1 14 9 V at 5 000 r min DCV 20 R B W Y 1 2 3 Inspect Charging coil resistance Out of specification Replace Tester lead White lead 1 Tester lead Ground 2 Charging coil resistance Tester select...

Page 312: ...the following inspection steps NOTE Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Check entire ignition system for connection Repair or replace Check TPS TPS coil Replace Check CDI unit TPS input voltage Replace OK OK No good No good No good ...

Page 313: ...0 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace TPS COIL INSPECTION 1 Inspect TPS coil resistance Out of specification Replace 2 Loosen Throttle stop screw 1 NOTE Turn out the throttle stop screw until the throt tle shaft is in the full close position Tester lead Blue lead 1 Tester lead Black lead 2 TPS coil resis...

Page 314: ...Yellow lead 1 Tester lead Black lead 2 TPS coil variable resistance Tester selec tor position Full closed Full opened kΩ 1 0 2 kΩ at 20 C 68 F 4 6 kΩ at 20 C 68 F TPS REPLACEMENT AND ADJUSTMENT 1 Remove TPS coupler Screw TPS 1 TPS 2 NOTE Loosen the screws TPS using the T25 bit 2 Replace TPS 3 Install TPS 1 Screw TPS 2 TPS coupler NOTE Align the slot a in the TPS with the projec tion b on the carbu...

Page 315: ...f function of the coupler Make sure that a short circuit does not develop between the terminals because it may cause damage to electrical compo nents 6 Start the engine Tester lead Yellow lead 3 Tester lead Black lead 4 7 Adjust TPS output voltage Adjustment steps Adjust the installation angle of the TPS 1 to obtain the specified output voltage NOTE Measure the output voltage accurately with a dig...

Page 316: ...he engine 1 EC694000 TPS INPUT VOLTAGE INSPECTION 1 Disconnect the TPS coupler 2 Start the engine 3 Inspect TPS input voltage Out of specification Replace the CDI unit Tester lead Blue lead 1 Tester lead Black Blue lead 2 TPS input voltage Tester selector position 4 6 V DCV 20 ...

Page 317: ... tool Check the bulb and bulb socket Replace the bulb and or bulb socket Check the lights switch Replace Check the AC magneto Lighting coil Replace Check the entire lighting sys tem proper for connections Repair or replace Check the rectifier regulator Out put voltage Replace Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 OK OK OK OK No good No goo...

Page 318: ...pecification Replace RECTIFIER REGULATOR INSPECTION 1 Connect the battery leads 2 Start the engine 3 Turn on the headlight and taillight by turn ing on the lights switch 4 Inspect Out put voltage Out of specification Replace rectifier regulator Tester lead Yellow lead 1 Tester lead Ground 2 Lighting coil resistance Tester selector position 0 224 0 336 Ω at 20 C 68 F Ω 1 Tester lead Yellow lead 1 T...

Page 319: ...best possi ble carburetor setting NOTE It is recommended to keep a record of all car buretor settings and external conditions e g atmospheric conditions track surface condi tions lap times to make future carburetor set ting easier WARNING The carburetor is a part of the fuel line Therefore be sure to install it in a well ventilated area away from flammable objects and any sources of fire Never loo...

Page 320: ...ged starting may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly Atmospheric conditions and carburetor settings The air density i e concentration of oxygen in the air determines the richness or lean ness of the air fuel mixture Therefore refer to the above table for mixture settings That is Hig...

Page 321: ...losed ı Fully open 1 2 3 4 1 4 1 8 1 2 3 4 Å ı Main system The FLATCR carburetor has a primary main jet This type of main jet is perfect for racing motorcycles since it supplies an even flow of fuel even at full load Use the main jet and the jet needle to set the carburetor 1 Jet needle 2 Pilot air jet 3 Needle jet 4 Main jet 5 Pilot jet 6 Pilot screw ...

Page 322: ...ottle Main jet adjustment The richness of the air fuel mixture at full throt tle can be set by changing the main jet 1 Except for USA If the air fuel mixture is too rich or too lean the engine power will drop resulting in poor accel eration Effects of changing the main jet reference Å Idle ı Fully open Standard main jet 150 160 1 4 1 2 3 4 10 150 10 160 140 Å ı ...

Page 323: ... the pilot screw only 1 2 of a turn in either direction To optimize the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this num ber as the factory set number of turns out Effects of adjusting the pilot screw reference Å Idle ı Fully open 1 2 1 4 turns ...

Page 324: ...ough engine operation is felt and the engine will not pick up speed smoothly In this case step up the jet needle clip by one groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and will not pick up speed quickly Step down the jet needle clip by one groove and move up the needle to enrich the mixture Effects of changing the jet needle g...

Page 325: ... the air fuel mixture when the throttle is 1 8 to 1 4 open Å Idle ı Fully open Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then it is further regulated by the area between the main nozzle and the jet needle The fuel flow relates to the diameter of the straight portion of the jet needle with the throt tle 1 8 to 1 4 op...

Page 326: ...14943 37 4MX 14943 87 4MX 14943 36 4MX 14943 86 4MX 14943 35 Pilot jet Rich STD STD Lean 52 50 48 45 42 40 4MX 14948 08 4MX 14948 07 4MX 14948 06 4MX 14948 05 4MX 14948 04 4MX 14948 03 Jet needle Rich STD Lean DUQ DUR DUS DUT DUU DUV DUW 5TJ 14916 D1 5TJ 14916 DR 5TJ 14916 DS 5TJ 14916 DT 5TJ 14916 DU 5TJ 14916 DV 5TJ 14916 DW Jet needle Rich STD Lean DUM DUN DUP DUQ DUR DUS DUT 5TJ 14916 DM 5TJ 1...

Page 327: ...top Check that the accelerator pump oper ates smoothly except for rich mixture symptom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower jet needle clip position 1 groove down 1 4 1 2 throttle Slow speed pick up Poor acceleration Raise jet needle clip position 1 groove up Closed to 1 4 throttle Hard breathing Speed down Use jet needle with ...

Page 328: ...uld be matched to the portion of the course that has the greatest effect on the race result In such a case run through the entire course while making notes of lap times to find the best balance then determine the secondary reduction ratio If a course has a long straight portion where a machine can run at maximum speed the machine is generally set such that it can develop its maximum revolutions to...

Page 329: ...0 00 5NY 25451 00 5GS 25452 50 5NY 25452 00 EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit Under a rainy muddy sandy or slippery condition the tire pressure should be lower for a larger area of contact with the road sur face Under a stony or hard road condition the tire pressure should be higher to prevent a flat tire Standard tire pressure ...

Page 330: ...teristic near the final stroke can be changed by changing the fork oil amount CAUTION Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the front fork to produce a noise at full rebound or the rider to feel some pres sure on his hands or body Alternatively too high oil level will develop unexpectedly early oil lock with the consequent shorter front fork travel ...

Page 331: ...er 3 2 adjustment washers Standard washer quantity Zero adjustment washers Extent of adjustment Zero 2 adjustment washers EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension take care so that the machine front and rear are balanced in posi tion etc when setting the front fork 1 Use of soft spring Generally a soft spring gives a soft ridi...

Page 332: ...come weaker resulting in lack of a sense of contact with the road surface or in a vibrating handlebar To set a stiff spring Change the rebound damping Turn in one or two clicks Change the compression damping Turn out one or two clicks Å Coverage of spring by weight ı Rider weight 1 Soft 2 Standard 3 Stiff SETTING ...

Page 333: ... spring TYPE thickness PART NUMBER T 2 3 mm 0 09 in 4SS 23364 L0 TYPE SPRING RATE SPRING PART NUMBER I D MARK slits SOFT 0 380 0 390 0 400 0 410 4SS 23141 10 4SS 23141 20 4SS 23141 30 4SS 23141 40 I I I II I III I STD 0 420 4SR 23141 L0 0 430 4SS 23141 60 III STD 0 440 5NL 23141 00 0 450 5BE 23141 L0 STD 0 460 5GR 23141 L0 STIFF 0 470 5GR 23141 00 II II TYPE SPRING RATE approx SPRING PART NUMBER I...

Page 334: ...ping EC72C001 Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and measure the length a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender holding bolt 3 Loosen the locknu...

Page 335: ... set length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring Set the soft spring for less rebound damping to compensate for its less spring load Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference 2 Use of stiff spring Set the soft spring for more rebound damping to compensate for its greater spring load Run with the ...

Page 336: ...he one whose overall length a does not exceed the standard as it may result in faulty performance Never use one whose overall length is greater than standard Å Coverage of spring by weight ı Rider weight 1 Soft 2 Standard 3 Stiff Length a of standard shock 490 5 mm 19 31 in SETTING ...

Page 337: ...212 00 5UN 22212 10 5UN 22212 20 Brown 1 Green 1 Red 1 260 260 260 STD 4 9 5UN 22212 30 Black 1 260 5 1 5UN 22212 40 Blue 1 260 STD 5 2 5UN 22212 90 Purple 1 260 STD 5 3 5UN 22212 50 Yellow 1 260 STIFF 5 5 5 7 5UN 22212 60 5UN 22212 70 Pink 1 White 1 260 260 TYPE SPRING RATE approx SPRING PART NUMBER I D COLOR POINT SPRING FREE LENGTH SOFT STIFF 4 5 4 7 4 9 5 1 5 3 5 5 5 7 5UN 22212 A0 5UN 22212 B...

Page 338: ...ession damping Oil level oil amount Spring Turn adjuster clockwise about 2 clicks to increase damping Increase oil level by about 5 10 mm 0 2 0 4 in Replace with stiff spring Stiff toward stroke end Oil level oil amount Decrease oil level by about 5 mm 0 2 in Soft toward stroke end bottoming out Oil level oil amount Increase oil level by about 5 mm 0 2 in Stiff initial movement Compression damping...

Page 339: ...d dragging Rebound damping Spring Turn adjuster counterclockwise about 2 clicks to decrease damping Replace with soft spring Poor road gripping Rebound damping Low compression damping High compression damp ing Spring set length Spring Turn adjuster counterclockwise about 2 clicks to decrease damping Turn adjuster clockwise about 1 clicks to increase damping Turn adjuster clockwise about 1 6 clicks...

Page 340: ...PRINTED IN JAPAN 2002 10 2 0 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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