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Yamaha YZ125 2009, Owner'S Service Manual

The Yamaha YZ125 2009 Owner's Service Manual is a comprehensive manual that provides detailed instructions and maintenance procedures for the Yamaha YZ125 2009 model. Easily download this essential manual for free from manualshive.com, ensuring you have access to all the necessary information to keep your bike in top-notch condition.

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5-12

FRONT BRAKE AND REAR BRAKE

DISASSEMBLING THE BRAKE MASTER CYLINDER

Order

Part name

Q'ty

Remarks

A. Front
B. Rear

1

Brake master cylinder cap

1

2

Diaphragm

1

3

Reservoir float

1

4

Push rod (Front)

1

5

Brake master cylinder boot

1

6

Circlip

1

Use a long nose circlip pliers.

7

Washer

1

8

Push rod (Rear)

1

9

Brake master cylinder kit

1

Summary of Contents for YZ125 2009

Page 1: ...OWNER S SERVICE MANUAL YZ125Y 1C3 28199 14 LIT 11626 22 54 2009 q Read this manual carefully before operating this vehicle ...

Page 2: ...Q Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold ...

Page 3: ...by Yamaha Motor Corporation U S A 1st Edition April 2008 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 22 54 ...

Page 4: ...ANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OP ERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWL EDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILI TIES AND THE RELIABI...

Page 5: ...ill any gasoline on the en gine or exhaust system Never refuel in the vi cinity of an open flame or while smoking GASOLINE CAN CAUSE INJURY If you should swallow some gasoline inhale excess gasoline vapors or allow any gasoline to get into your eyes contact a doctor imme diately If any gasoline spills onto your skin or clothing immediately wash skin areas with soap and water and change your clothe...

Page 6: ...YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY ...

Page 7: ...minimum weights for motocross machines are for the class 125 cc minimum 88 kg 194 lb for the class 250 cc minimum 98 kg 216 lb for the class 500 cc minimum 102 kg 225 lb In modifying your machine e g for weight re duction take note of the above limits of weight ...

Page 8: ...wn to find the required fore edge symbol mark and go to a page for required item and description MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The informa tion has been complied to provide the mechanic with an easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspection operations In t...

Page 9: ...iagram 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 are given on the next page 4 A job instruction chart 4 accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 For jobs requiring more information the st...

Page 10: ...strated symbols 8 to 14 in the exploded diagrams indicate grade of lubricant and loca tion of lubrication point 8 Apply engine mixing oil 9 Apply transmission oil 10 Apply molybdenum disulfide oil 11 Apply brake fluid 12 Apply lightweight lithium soap base grease 13 Apply molybdenum disulfide grease 14 Apply silicone grease Illustrated symbols 15 to 16 in the exploded diagrams indicate where to ap...

Page 11: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 ELECTRICAL 6 TUNING 7 ...

Page 12: ...OOLS 1 8 CONTROL FUNCTIONS 1 11 STARTING AND BREAK IN 1 13 TORQUE CHECK POINTS 1 15 CLEANING AND STORAGE 1 16 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 TIGHTENING TORQUES 2 9 CABLE ROUTING DIAGRAM 2 15 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 5 ENGINE 3 6 CHASSIS 3 13 ELECTRICAL 3 29 ...

Page 13: ...N 4 17 CLUTCH 4 28 KICK SHAFT AND SHIFT SHAFT 4 34 YPVS GOVERNOR 4 42 WATER PUMP 4 45 CDI MAGNETO 4 48 ENGINE REMOVAL 4 51 CRANKCASE AND CRANKSHAFT 4 55 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 62 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 2 FRONT BRAKE AND REAR BRAKE 5 9 FRONT FORK 5 23 HANDLEBAR 5 36 STEERING 5 43 SWINGARM 5 48 REAR SHOCK ABSORBER 5 55 ...

Page 14: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 2 IGNITION SYSTEM 6 4 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 10 ...

Page 15: ...1 1 LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle 1 ...

Page 16: ... to change without notice 1 Clutch lever 2 Engine stop switch 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 Kickstarter crank 8 Fuel tank 9 Radiator 10 Coolant drain bolt 11 Check bolt Transmission oil level 12 Rear brake pedal 13 Valve joint 14 Fuel cock 15 Air filter 16 Drive chain 17 Shift pedal 18 Starter knob 19 Front fork ...

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

Page 18: ... Remove this sidestand before starting out VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose In this installation make sure the arrow fac es the fuel tank and also downward COLLAR tool for YPVS This collar 1 is used to remove and install the push rod of the engine NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke ...

Page 19: ... 4 During the machine disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help assure that all parts are cor rectly reinstalled 5 Keep away from fire ALL REPLACEMENT PARTS 1 We recommend to use Yamaha genuine parts for all replacements Use oil and or grease recommended by Yamaha for as sembly and adjustment GASKETS OIL SEALS AND O RI...

Page 20: ...ightweight lithium base grease to the seal lip s Oil the bear ings liberally when installing Do not use compressed air to spin the bear ings dry This causes damage to the bearing surfaces CIRCLIPS 1 All circlips should be inspected carefully be fore reassembly Always replace piston pin clips after one use Replace distorted cir clips When installing a circlip 1 make sure that the sharp edged corner...

Page 21: ...eck that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 6 Connect Connector The two connectors click together 7 Check for continuity with a tester If there in no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness For a field remedy use a contact revitalizer available on the ...

Page 22: ...890 Tool name Part number How to use Illustration Crankcase separating tool YU 1135 A 90890 01135 These tool is used to remove the crankshaft from either case Flywheel puller YM 1189 90890 01189 This tool is used to remove the flywheel magneto Rotor holding tool YU 1235 90890 01235 This tool is used when loos ening or tightening the fly wheel magneto securing nut Dial gauge and stand YU 3097 90890...

Page 23: ...ester adapter YU 33984 90890 01352 These tools are used for checking the cooling system Flywheel puller YU 33270 B 90890 01362 These tool is used to split the crankcase Steering nut wrench YU 33975 90890 01403 This tool is used when tighten the steering ring nut to speci fication Cap bolt wrench YM 01500 90890 01500 This tool is used to loosen or tighten the base valve Cap bolt ring wrench YM 0150...

Page 24: ...90 03112 Use this tool to inspect the coil resistance output voltage and amperage Clutch holding tool YM 91042 90890 04086 This tool is used to hold the clutch when removing or in stalling the clutch boss secur ing nut Dynamic spark tester YM 34487 Ignition checker 90890 06754 This instrument is necessary for checking the ignition sys tem components YAMAHA Bond No 1215 ThreeBond No 1215 90890 8550...

Page 25: ...ears can be shifted by using the shift pedal 1 on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter crank 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 crank so the engine can be started in any gear if the clutch is disen gaged In normal practic...

Page 26: ...s position fuel will not flow Always return the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position STARTER KNOB CHOKE When cold the engine requires a richer air fuel mixture for starting A separate starter circuit which is controlled by the starter knob 1 sup plies this mixture ...

Page 27: ...closed start the engine by kicking the kick starter forcefully with firm stroke 4 Run the engine at idle or slightly higher until it warms up this usually takes about one or two minutes 5 The engine is warmed up when it responds normally to the throttle with the starter knob CHOKE turned off Do not warm up the engine for extended pe riods of time STARTING A WARM ENGINE Do not operate the starter k...

Page 28: ...ly reassemble the top end 8 Drain the break in oil fuel mixture from the fuel tank and refill with the specified mix 9 Restart the engine and check the operation of the machine throughout its entire operat ing range Stop and check the spark plug condition Restart the machine and operate it for about 10 to 15 more minutes The ma chine will now be ready to race After the break in or before each race...

Page 29: ...lower bracket Rear For link type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of wheel axle Tightening of axle holder Rear Tightening of wheel axle Wheel to rear wheel sprocket Brake Front Brake caliper to f...

Page 30: ...hain with a paper towel and lubricate the chain to prevent rust 7 Clean the seat with a vinyl upholstery clean er to keep the cover pliable and glossy 8 Automotive wax may be applied to all paint ed or chromed surfaces Avoid combination cleaner waxes as they may contain abra sives 9 After completing the above start the engine and allow it to idle for several minutes STORAGE If your machine is to b...

Page 31: ...arrangement Single cylinder forward inclined Displacement 124 cm3 4 36 Imp oz 4 19 US oz Bore stroke 54 54 5 mm 2 126 2 146 in Compression ratio 8 6 10 7 1 Starting system Kick starter Lubrication system Premix 30 1 Yamalube 2 R Oil type or grade 2 stroke Transmission oil Yamalube 4 10W 40 or SAE 10W 40 type SE motor oil Periodic oil change 0 66 L 0 58 Imp qt 0 69 US qt Total amount 0 70 L 0 62 Im...

Page 32: ...adle Caster angle 25 5 25 6 Trail 105 mm 4 13 in 107 mm 4 21 in Tire Type With tube Size front 80 100 21 51M Size rear 100 90 19 57M Tire pressure front and rear 100 kPa 1 0 kgf cm2 15 psi Brake Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link ...

Page 33: ...t 0 01 mm 0 0004 in Piston Piston size 53 957 53 972 mm 2 1243 2 1249 in Measuring point H 17 5 mm 0 69 in Piston clearance 0 040 0 045 mmm 0 0016 0 0018 in 0 1 mm 0 004 in Piston offset 0 5 mm 0 019 in EX side Piston pin Piston pin outside diameter 14 995 15 000 mm 0 5904 0 5906 in 14 975 mm 0 5896 in Piston ring Sectional sketch Plain B 1 0 mm 0 039 in T 2 35 mm 0 093 in End gap installed 0 5 0 ...

Page 34: ...t 0 2 mm 0 008 in Clutch spring free length 40 1 mm 1 579 in 38 1 mm 1 500 in Quantity 5 Clutch housing thrust clearance 0 15 0 26 mm 0 006 0 010 in Clutch housing radial clearance 0 014 0 046 mm 0 0006 0 0018 in Clutch release method Inner push cam push Transmission Main axle deflection limit 0 01 mm 0 0004 in Drive axle deflection limit 0 01 mm 0 0004 in Shifter Shifting type Cam drum and guide ...

Page 35: ...Starter jet G S 80 Fuel level F L 9 5 10 5 mm 0 37 0 41 in Reed valve Thickness 0 47 mm 0 019 in Valve stopper height 8 2 8 6 mm 0 323 0 339 in Valve bending limit 0 2 mm 0 008 in Cooling Radiator core size Width 107 8 mm 4 24 in Height left 240 mm 9 45 in Height right 220 mm 8 66 in Thickness 32 mm 1 26 in Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2 13 5 17 8 psi Radiator capacity t...

Page 36: ... 89 in Front fork top end 5 mm 0 2 in Rear suspension USA CDN ZA AUS NZ EUROPE Shock absorber travel 131 5 mm 5 18 in Spring free length Approx 265 mm 10 43 in Fitting length I D mark Red 1 258 mm 10 16 in 252 mm 9 92 in I D mark Red 2 264 mm 10 39 in 258 mm 10 16 in I D mark Red 3 255 5 mm 10 06 in 249 5 mm 9 82 in Preload length Min Max 1 5 13 mm 0 06 0 51 in Spring rate STD K 46 0 N mm 4 70 kg ...

Page 37: ...ad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 9 52 mm 0 375 in Caliper cylinder inside dia 22 65 mm 0 892 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 5 mm 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 2...

Page 38: ...t 20 C 68 F Green White Black Red Charging coil 2 resistance color 44 66 Ωat 20 C 68 F Black Green Blue Pickup coil resistance color 248 372 Ωat 20 C 68 F White Blue White Red CDI unit model manufacturer 1C3 10 YAMAHA Ignition coil Model manufacturer 1C3 00 YAMAHA Minimum spark gap 6 mm 0 24 in Primary winding resistance 0 24 0 36 Ωat 20 C 68 F Secondary winding resistance 5 7 8 5 kΩat 20 C 68 F S...

Page 39: ...2 9 Water pump housing cover M6 1 0 4 10 1 0 7 2 Coolant drain bolt M6 1 0 1 10 1 0 7 2 Radiator M6 1 0 6 10 1 0 7 2 Radiator panel M6 1 0 2 10 1 0 7 2 Radiator hose clamp M6 1 0 8 2 0 2 1 4 Air filter element M6 1 0 1 2 0 2 1 4 Carburetor joint M6 1 0 4 10 1 0 7 2 Carburetor joint clamp M4 0 7 1 2 0 2 1 4 Air filter joint clamp M4 0 7 1 2 0 2 1 4 Air filter case M6 1 0 4 8 0 8 5 8 Air filter guid...

Page 40: ...er Silencer and frame M6 1 0 2 12 1 2 8 7 Fiber For USA and CDN M6 1 0 2 10 1 0 7 2 Fiber Except for USA and CDN M6 1 0 4 10 1 0 7 2 Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Upper bracket and outer tube M8 1 25 4 21 2 1 15 Lower bracket and outer tube M8 1 25 4 21 2 1 15 Upper bracket and steering st...

Page 41: ...xle and axle nut M16 1 5 1 105 10 5 75 Front wheel axle holder M8 1 25 4 21 2 1 15 Front brake disc and wheel hub M6 1 0 6 12 1 2 8 7 Rear brake disc and wheel hub M6 1 0 6 14 1 4 10 Footrest bracket and frame M10 1 25 4 55 5 5 40 Brake pedal mounting M8 1 25 1 26 2 6 19 Rear brake master cylinder and frame M6 1 0 2 10 1 0 7 2 Rear brake master cylinder cap M4 0 7 2 2 0 2 1 4 Rear brake hose union...

Page 42: ...in support and swingarm M6 1 0 3 7 0 7 5 1 Seal guard and swingarm M5 0 8 4 6 0 6 4 3 Cable guide and frame M5 0 8 2 4 0 4 2 9 Fuel tank boss and frame M10 1 25 2 20 2 0 14 Fuel tank M6 1 0 2 10 1 0 7 2 Fuel tank and fuel cock M6 1 0 2 4 0 4 2 9 Fuel tank and seat set bracket M6 1 0 1 7 0 7 5 1 Fuel tank and hooking screw fitting band M6 1 0 1 7 0 7 5 1 Fuel tank and fuel tank bracket M6 1 0 4 7 0...

Page 43: ...warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A Nut B Bolt TORQUE SPECIFICA TION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17...

Page 44: ...imeter 10 2 meter Length kg kilogram 103 gram Weight N Newton 1 kg m sec2 Force Nm Newton meter N m Torque m kg Meter kilogram m kg Torque Pa Pascal N m2 Pressure N mm Newton per millimeter N mm Spring rate L Liter Volume or capacity cm3 Cubic centimeter Volume or capacity r min Revolution per minute Engine speed ...

Page 45: ...MEMO ...

Page 46: ...2 15 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM ...

Page 47: ...amp the throttle cable and high tension cord to the frame F Clamp the clutch cable to the left engine bracket Clamp the clutch cable below the positioning grommet G Pass the air vent hose back of the throttle cable H Pass the air vent hose overflow hose and crankcase breather hose between the frame and connecting rod I Pass the radiator breather hose and YPVS breather hose outside the engine brack...

Page 48: ...2 17 CABLE ROUTING DIAGRAM ...

Page 49: ...In so doing clamp the ignition coil lead and ENGINE STOP button lead at their protecting tubes Tighten the clamp so that the EN GINE STOP button lead is not pulled when the handlebar is turned to the right and left D Pass the CDI magneto lead and radiator breather hose between the frame and the radiator right E Clamp the CDI magneto lead to the frame at its locating tape F Bring the connector cove...

Page 50: ...2 19 CABLE ROUTING DIAGRAM ...

Page 51: ...tion directs as shown and lightly touches the projection on the caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe por tion directs as shown and lightly touches the projection on the master cylinder ...

Page 52: ...2 21 CABLE ROUTING DIAGRAM ...

Page 53: ...ke hose so that its pipe por tion directs as shown and lightly touches the projection on the master cylinder B Pass the ENGINE STOP button lead in the middle of the clutch holder C Clamp the ENGINE STOP button lead to the handlebar D Pass the brake hose in front of the number plate and through the cable guide E Pass the clutch cable through the cable guide on the number plate ...

Page 54: ...hird Every fifth As re quired Remarks PISTON Inspect and clean Inspect crack Replace Inspect carbon deposits and eliminate them PISTON RING Inspect Check ring end gap Replace PISTON PIN SMALL END BEARING Inspect Replace CYLINDER HEAD Inspect carbon deposits and eliminate them Inspect and clean Check gasket Retighten CYLINDER Inspect and clean Inspect score marks Replace Inspect wear YPVS Inspect a...

Page 55: ...m 1 9 2 3 in Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap opera tion Replace coolant Every two years Inspect hoses OUTSIDE NUTS AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Use foam air filter oil or equiva lent oil Replace FRAME Clean and inspect FUEL TANK COCK Clean and inspect Item After break in Every ra...

Page 56: ...l Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect and adjust Lube After rain ride Molybdenum disulfide grease Replace spring seat Every one year Retighten DRIVE CHAIN GUIDE AND ROLLERS Inspect SWINGARM Inspect lube and retighten Molybdenum disulfide grease RELAY ARM CONNECT ING ROD Inspect l...

Page 57: ...S 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 con nection Lubricate Yamaha cable lube or SAE 10W 40 motor oil Item After break in Every race Every third Every fifth As re quired Remarks ...

Page 58: ...k drive chain slack and alignment Check that the drive chain is lubricated properly P 3 18 20 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 24 25 Steering Check that the handlebar can be turned smoothly and have no excessive play P 3 25 27 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 2...

Page 59: ...on a level place and hold it in an upright position 2 Remove Radiator cap 3 Check Coolant level a Coolant level low Add coolant 1 Radiator CHANGING THE COOLANT Do not remove the radiator cap when the en gine is hot Take care so that coolant does not splash on painted surfaces If it splashes wash it away with water 1 Place a container under the engine 2 Remove Coolant drain bolt 1 3 Remove Radiator...

Page 60: ...k Coolant level Coolant level low Add coolant CHECKING THE RADIATOR CAP 1 Inspect Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits 3 Clean or replace CHECKING THE RADIATOR CAP OPENING PRESSURE 1 Attach Radiator cap tester 1 and adapter 2 Apply water on the radiator cap seal 3 Radiator cap 2 Apply the specified pressure 3 Inspect Pressure Impossible to maintain the...

Page 61: ... specification Adjust 2 Adjust Clutch lever free play Clutch lever free play adjustment steps a Loosen the locknuts 1 b Turn the adjuster 2 until free play a is within the specified limits c Tighten the locknuts Before adjustment expose the adjuster by moving the boot 3 and cap 4 away Make minute adjustment on the lever side us ing the adjuster 5 After adjustment check proper operation of clutch l...

Page 62: ...the throttle cable free play start the engine and turn the handlebar to right and left and make sure that the engine idling does not run faster LUBRICATING THE THROTTLE 1 Remove Cap cover 1 Throttle cable cap 2 2 Apply Lithium soap base grease On the throttle cable end a tube guide ca ble winding portion b and roller sliding sur face c 3 Install Throttle cable cap Cap cover CLEANING THE AIR FILTER...

Page 63: ...ing the element Leaving too much of solvent in the ele ment may result in poor starting 3 Inspect Air filter element Damage Replace 4 Apply Foam air filter oil or equivalent oil to the ele ment Squeeze out the excess oil Element should be wet but not dripping 5 Install Air filter guide 1 Align the projection a on filter guide with the hole b in air filter element 6 Apply Lithium soap base grease O...

Page 64: ...ger Wait until the oil cools down Oil flows out Oil level is correct Oil does not flow out Oil level is low Add transmission oil until oil flows out c Inspect the gasket oil check bolt replace if damaged d Tighten the oil check bolt CHANGING THE TRANSMISSION OIL 1 Start the engine and warm it up for several minutes and wait for five minute 2 Place the machine on a level place and hold it on uprigh...

Page 65: ...2 Adjust Engine idling speed Adjustment steps a Loosen the locknut 1 b Turn the throttle stop screw 2 until the en gine runs at the lowest possible speed c Tighten the locknut CHECKING THE EXHAUST PIPE 1 Inspect O ring 1 Damage Replace Install the O rings with their depressed a fac ing outward Recommended oil Yamalube 4 10W 40 or SAE 10W 40 type SE motor oil Oil capacity periodic oil change 0 66 L...

Page 66: ... sever al times f Pull the lever in or push down on the pedal Hold the lever or pedal in position g Loosen the bleed screw and allow the lever or pedal to travel towards its limit h Tighten the bleed screw when the lever or pedal limit has been reached then release the lever or pedal i Repeat steps e to h until of the air bub bles have been removed from the system If bleeding is difficult it may b...

Page 67: ...nt steps a Loosen the locknut 1 b Turn the adjusting nut 2 until the pedal height a is within specified height c Tighten the locknut Adjust the pedal height between the maxi mum A and the minimum B as shown In this adjustment the bolt 3 end b should protrude out of the threaded por tion 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 th...

Page 68: ... tainer under its end f Loosen the bleed screw and push the brake caliper piston in Do not reuse the drained brake fluid g Tighten the bleed screw h Install the brake pads 7 and pad pin Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 Bleed screw 6 Nm 0 6 m kg 4 3 ...

Page 69: ...ad thickness a Out of specification Replace as a set 2 Replace Brake pad Brake pad replacement steps a Remove the protector 1 and pad pin plug 2 b Loosen the pad pin 3 c Remove the rear wheel 4 and brake caliper 5 Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 d Remove the pad pin 6 and brake pads 7 e Connect the transparent hose 8 to the bleed screw 9 and place the suitable con tain...

Page 70: ...rake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake pedal operation A softy or spongy feeling Bleed brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM section CHECKING THE REAR BRAKE PAD INSULATOR 1 Remove Brake pad Refer to CHECKING AND REPLACING THE REAR BRAKE PADS section 2 Inspect Rear brake pad insulator 1 Damage Replace CHECKING THE BRAKE FLUID LEVEL 1 Plac...

Page 71: ...e wear Replace Replace the drive sprocket rear wheel sprock et and drive chain as a set CHECKING THE DRIVE CHAIN 1 Measure Drive chain length 15 links a Out of specification Replace While measuring the drive chain length push down on the drive chain to increase its ten sion Measure the length between drive chain roller 1 and 16 as shown Perform this measurement at two or three dif ferent places 2 ...

Page 72: ... or adjust the drive chain slack with the rear wheel in this tight chain position 3 Adjust Drive chain slack Drive chain slack adjustment steps a Loosen the axle nut 1 and locknuts 2 b Adjust the drive chain slack by turning the adjusters 3 c Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of the drive chain puller alignment NOTICE Impro...

Page 73: ...w driver and be careful not to damage the inner fork tube and dust seal 2 Clean Dust seal a Oil seal b Clean the dust seal and oil seal after every run Apply the lithium soap base grease on the in ner tube RELIEVING THE FRONT FORK INTERNAL PRESSURE If the front fork initial movement feels stiff dur ing a run relieve the front fork internal pres sure 1 Elevate the front wheel by placing a suitable ...

Page 74: ...um extent of adjustment The ad juster may be damaged Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability CHECKING THE REAR SHOCK ABSORBER 1 Inspect Swingarm smooth action Abnormal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace Stiffer a Increase the rebound damp ing force Turn t...

Page 75: ...d mud from around the locknut and adjuster before adjust ment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster Never attempt to turn the adjuster beyond the maximum or minimum setting e Tighten the locknut Standard fitting length I D MARK Q TY Length Red 1 Red 2 Red 3 258 mm 10 16 in 252 mm 9 92 in 264 mm 10 39 in 258 mm 10 16 in 255 5 mm 10 06 in 249 5 mm 9 82 in...

Page 76: ... turned in position Which align the punch mark a on the adjuster with the punch mark b on the high compression damping adjuster Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Rear frame upper 32 Nm 3 2 m kg 23 ft lb Rear frame lower 29 Nm 2 9 m kg 21 ft lb Stiffer a Increase the rebound damp ing force Turn the adjuster 1 in Softer b Decrease...

Page 77: ... Out of specification Adjust Check the tire while it is cold Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low A tilted tire valve stem indicates that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position Stiffer a Increase the high compre...

Page 78: ...ter break in CHECKING THE WHEELS 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace 2 Inspect Bearing free play Exist play Replace CHECKING AND ADJUSTING THE STEERING HEAD 1 Place a stand under the engine to raise the front wheel off theground WARNING Se curely support the vehicle so that there is no danger of it falling over 2 Check Steering stem Grasp the bottom of the ...

Page 79: ...bearings h Install the washer 5 upper bracket 6 washer 7 steering stem nut 8 handlebar 9 handlebar upper holder 10 and num ber plate 11 The handlebar upper holder should be in stalled with the punched mark a forward Install the handlebar so that the marks b are in place on both sides Install the handlebar so that the projection c of the handlebar upper holder is positioned at the mark on the handl...

Page 80: ...3 27 CHASSIS ...

Page 81: ...ndlebar contact 6 Drive chain 7 Throttle roller cable guide 8 Throttle roller sliding surface 9 Tube guide cable winding portion 10 Throttle cable end 11 Clutch cable end A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W 40 motor oil or suitable chain lubricants C Lubricate the following areas with high quality lightweight lithium soap base grease Wipe off any excess grease and av...

Page 82: ...alling a spark plug clean the gas ket surface and plug surface Finger tighten a the spark plug before torqu ing to specification b CHECKING THE IGNITION TIMING 1 Remove Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Spark plug Crankcase cover left 2 Attach Dial gauge 1 Spark plug hole dial stand 2 3 Rotate the magneto rotor 1 until the piston reaches top dead center TDC...

Page 83: ...ming Punch mark a on rotor should be aligned with punch mark b on stator Not aligned Adjust 7 Adjust Ignition timing Adjustment steps a Loosen the screws stator 1 b Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator c Tighten the screws stator Ignition timing B T D C 0 48 mm 0 019 in Screw stator 7 Nm 0 7 m kg 5 1 ft lb ...

Page 84: ...vicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ...

Page 85: ...lt fuel tank 2 5 Fuel tank 1 6 Left side cover 1 Refer to removal section 7 Right side cover 1 Refer to removal section 8 Number plate 1 Refer to removal section 19 Nm 1 9 m kg 13 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 19 Nm 1 9 m kg 13 ft lb 6 Nm 0 6 m kg 4 3 ft l...

Page 86: ... air filter case REMOVING THE NUMBER PLATE 1 Remove Bolt number plate Number plate 1 The projection a is inserted into the band of the number plate Pull the band off the projec tion before removal Remove the clutch cable 2 from the cable guide b on the number plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off the projection ...

Page 87: ...VERS section 1 Bolt silencer 2 2 Washer ø 22 mm 0 87 in 1 2 Washer ø 26 mm 1 02 in 1 3 Silencer 1 4 Collar L 13 0 mm 0 51 in 1 4 Collar L 15 5 mm 0 61 in 1 5 Collar L 13 5 mm 0 53 in 1 6 Grommet front 1 7 Grommet rear 1 8 Tension spring 2 9 Bolt exhaust pipe 2 10 Exhaust pipe 1 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft...

Page 88: ...ipe Fully apply Quick gasket Yamaha bond No 1215 or equivalent as shown 5 Install Bolt fiber 1 Silencer 2 Bolt silencer front 3 Bolt silencer rear 4 Side cover right A For USA and CDN B Except for USA and CDN Yamaha bond No 1215 Three Bond No 1215 90890 85505 Bolt fiber 10 Nm 1 0 m kg 7 2 ft lb Bolt silencer front 12 Nm 1 2 m kg 8 7 ft lb Bolt silencer rear 12 Nm 1 2 m kg 8 7 ft lb Side cover righ...

Page 89: ...AT FUEL TANK AND SIDE COVERS section 1 Radiator guard 2 2 Radiator hose clamp radiator hose 1 3 2 Only loosening 3 Radiator hose 2 1 4 Left radiator 1 5 Radiator hose 4 1 6 Right radiator 1 7 Radiator hose 1 1 8 Radiator hose 3 1 9 Radiator breather hose 1 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2 m kg 1 4 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2 m kg 1 4 ft lb ...

Page 90: ...core 1 Obstruction Blow out with compressed air through rear of the radiator Bent fin Repair replace INSTALLING THE RADIATOR 1 Install Radiator breather hose 1 Radiator hose 3 2 Radiator hose 1 3 To right radiator 4 Clamp the radiator hose in the direction as shown 2 Install Right radiator 1 Washer 2 Bolt right radiator 3 Radiator hose 4 4 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 3 ...

Page 91: ...Radiator hose clamp 1 3 5 5 Install Radiator guard 1 Bolt radiator guard 2 Fit the hook a on the inner side first into the ra diator Radiator hose clamp 1 3 2 Nm 0 2 m kg 1 4 ft lb Bolt radiator guard 10 Nm 1 0 m kg 7 2 ft lb ...

Page 92: ...marks Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Clamp carburetor joint 2 Loosen the screw carburetor joint 2 Carburetor 1 3 Carburetor joint 1 4 Reed valve assembly 1 5 Stopper reed valve 2 6 Reed valve 2 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 1 Nm 0 1 m kg 0 7 ft lb ...

Page 93: ...er top 1 Refer to removal section 2 Throttle valve 1 3 Needle holder 1 4 Jet needle 1 5 Float chamber 1 6 Needle jet cover 1 7 Float pin 1 8 Float 1 9 Valve seat 1 10 Main jet 1 11 Main jet holder 1 12 Pilot jet 1 13 Starter plunger 1 14 Throttle stop screw 1 15 Pilot air screw 1 4 Nm 0 4 m kg 2 9 ft lb ...

Page 94: ...ARBURETOR 1 Inspect Carburetor body Contamination Clean When cleaning the main air passage a do not blow air at the filter side because it will clog the passage with mud or sand Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire When cleaning the main air passage blow air through it while covering the nozzle with a clean rag 2 Inspect Ma...

Page 95: ...lter 1 Damage Replace Inspect the filter as it is assembled to the carbu retor Do not remove the filter except when re placing it MEASURING AND ADJUSTING THE FUEL LEVEL 1 Measure Fuel level a Out of specification Adjust Fuel level Measurement and adjustment steps a Remove the drain plug b Connect the fuel level gauge adapter 2 and fuel level gauge 1 to the float chamber c Hold the fuel level gauge...

Page 96: ...t 1 Damage Replace CHECKING THE REED VALVE 1 Measure Reed valve bending a Out of specification Replace 2 Measure Valve stopper height a Out of specification Adjust stopper Re place valve stopper INSTALLING THE REED VALVE 1 Install Reed valve 1 Stopper reed valve 2 Screw reed valve 3 Install the reed valve with the reed valve bending as shown Note the cut a in the lower corner of the reed and stopp...

Page 97: ... pilot air screw until it is lightly seated b Back out it by the specified number of turns 2 Install Starter plunger 1 3 Install Main jet holder 1 Main jet 2 Pilot jet 3 Valve seat 4 Screw valve seat 5 4 Install Needle valve 1 Float 2 Float pin 3 Screw float pin 4 Needle jet cover 5 After installing the needle valve to the float in stall them to the carburetor Check the float for smooth movement B...

Page 98: ...le valve 6 While compressing the spring connect the throttle cable Align the projection a on the ring with the groove b in the needle holder 7 8 Install Mixing chamber top 1 Screw mixing chamber top 2 To carburetor 3 After installing check the throttle grip for smooth movement 9 Install Air vent hose 1 Overflow hose 2 Clamp 3 Pass the air vent hose at the rear on the air cleaner side of the thrott...

Page 99: ...ts 2 Tighten Bolt air filter joint 1 Bolt carburetor joint 2 3 Clamp Air vent hose 1 Overflow hose 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Adjust Idle speed Refer to ADJUSTING THE ENGINE IDLING SPEED section in the CHAPTER 3 Bolt air filter joint 2 Nm 0 2 m kg 1 4 ft lb Bolt carburetor joint 2 Nm 0 2 m kg 1 4 ft lb ...

Page 100: ...D SI LENCER section Radiator Refer to RADIATOR section 1 Spark plug 1 2 Engine bracket 2 3 Nut cylinder head 5 Loosen each nut 1 4 turn and re move them after all nuts are loos ened 4 Cylinder head 1 5 Power valve housing 1 6 Push rod 1 Refer to removal section 7 Nut cylinder 4 8 Cylinder 1 5 Nm 0 5 m kg 3 6 ft lb 4 Nm 0 4 m kg 2 9 ft lb 13 Nm 1 3 m kg 9 4 ft lb 28 Nm 2 8 m kg 20 ft lb 20 Nm 2 0 m...

Page 101: ...3 Piston 1 Refer to removal section 4 Small end bearing 1 Refer to removal section 5 Piston ring 1 Refer to removal section 6 Power valve cover 1 7 Thrust plate 1 8 Bolt link lever 1 9 Valve holder 1 10 Valve shaft 1 11 Collar 2 12 Link lever 1 13 Spring 2 14 Power valve 1 1 15 Power valve 2 1 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 8 Nm 0 8 m kg 5 8 ft lb 5 Nm 0 5 m kg 3 6 ft lb ...

Page 102: ...g each piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and the piston pin is still dif ficult to remove use the piston pin puller set 4 Do not use a hammer to drive the piston pin out 3 Remove Piston ring 1 Take care not to scratch the piston or damage the piston ring by expanding it more than nec essary CHECKING THE CYLINDER HEAD 1 Eliminate Carbon deposit...

Page 103: ...veral times CHECKING THE CYLINDER 1 Eliminate Carbon deposits Use a rounded scraper 1 Do not use a sharp instrument Avoid scratch ing the aluminum 2 Inspect Cylinder inner surface Score marks Repair or replace Use 400 600 grit wet sandpaper Do not rebore the cylinder 3 Measure Cylinder bore C Use cylinder gauge 1 Out of limit Replace Measure the cylinder bore C in parallel A B C to and at right an...

Page 104: ...the specific distance a from the bottom edge Out of specification Replace CHECKING THE PISTON PIN AND SMALL END BEARING 1 Inspect Piston pin Small end bearing Signs of heat discoloration Replace 2 Measure Piston pin outside diameter Use micrometer 1 Out of limit Replace Distance a Piston dia 17 5 mm 0 69 in 53 957 53 972 mm 2 1243 2 1249 in Piston pin outside diameter Standard Limit 14 995 15 000 ...

Page 105: ...ired CHECKING THE PISTON RING 1 Install Piston ring Into the cylinder Push the ring with the piston crown 2 Measure End gap Use a thickness gauge 1 Out of limit Replace 3 Measure Side clearance Use a thickness gauge 1 Out of limit Replace piston and or ring Check at several points CHECKING THE PISTON CLEARANCE 1 Calculate Piston clearance Out of limit Replace piston and piston ring and or cylinder...

Page 106: ...Damage Replace Spring 6 Broken Replace CHECKING THE POWER VALVE HOLE ON CYLINDER 1 Remove Carbon deposits From power valve hole surface a Piston clearance Standard Limit 0 040 0 045 mm 0 0016 0 0018 in 0 1 mm 0 004 in Cylinder mark a Cylinder size A 54 000 54 002 mm 2 1260 2 1261 in B 54 004 54 006 mm 2 1261 2 1262 in C 54 008 54 010 mm 2 1263 2 1264 in D 54 012 54 014 mm 2 1265 2 1265 in Piston m...

Page 107: ...er portion a facing inward Apply the lithium soap base grease on the oil seal lip 3 Install Thrust plate 1 Screw thrust plate 2 4 Check Power valve smooth movement Unsmooth movement Repair or replace 5 Install Gasket power valve cover 1 Power valve cover 2 Screw power valve cover 3 YPVS breather hose 4 Install the power valve cover so that the arrow mark a faces upward Install the clamp of the YPV...

Page 108: ...il onto the bearing crank shaft and connecting rod and connecting rod big end washers Install the gasket with the seal print side to ward the crankcase 3 Install Piston 1 Piston pin 2 Piston pin clip 3 The arrow a on the piston dome must point to exhaust side Before installing the piston pin clip cover the crankcase with a clean rag to prevent the pis ton pin clip from falling into the crankcase c...

Page 109: ... one hand while compressing the piston ring with the other hand After installing check the smooth movement of the piston 3 Install Nut cylinder 1 Tighten the nuts in stage using a crisscross pattern 4 Install Collar 1 Push rod 2 Plain washer 3 Bolt push rod 4 Set the collar 5 included in owner s tool kit to install the bolt push rod Do not forget to remove the collar Nut cylinder 30 Nm 3 0 m kg 22...

Page 110: ...her 2 Nut cylinder head 3 Tighten the nuts cylinder head in stage using a crisscross pattern 8 Install Engine bracket 1 Bolt engine bracket 2 Engine mounting bolt upper 3 9 Install Spark plug 1 Spark plug cap 2 Bolt power valve housing 4 Nm 0 4 m kg 2 9 ft lb Nut cylinder head 28 Nm 2 8 m kg 20 ft lb Bolt engine bracket 34 Nm 3 4 m kg 24 ft lb Engine mounting bolt upper 34 Nm 3 4 m kg 24 ft lb Spa...

Page 111: ...ION OIL section in the CHAP TER 3 Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Bolt clutch spring 6 3 Clutch spring 6 4 Pressure plate 1 5 Friction plate 8 6 Clutch plate 7 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 112: ...ring 1 5 Ball 1 6 Push rod 2 1 7 Nut clutch boss 1 Refer to removal section 8 Lock washer 1 Refer to removal section 9 Clutch boss 1 Refer to removal section 10 Thrust washer D ø34mm 1 34 in 1 11 Primary driven gear 1 12 Bearing 1 13 Thrust washer D ø34mm 1 34 in 1 14 Push lever shaft 1 80 Nm 8 0 m kg 58 ft lb ...

Page 113: ...KING THE PRIMARY DRIVEN GEAR 1 Check Circumferential play Free play exists Replace Gear teeth a Wear damage Replace CHECKING THE CLUTCH SPRINGS 1 Measure Clutch spring free length a Out of specification Replace springs as a set CHECKING THE FRICTION PLATES 1 Measure Friction plate thickness Out of specification Replace friction plate as a set Measure at all four points Clutch holding tool YM 91042...

Page 114: ... 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Wear damage bend Replace INSTALLING THE PUSH LEVER SHAFT 1 Install Push lever shaft 1 Apply the lithium soap base grease on the oil seal lip and push lever shaft INSTALLING THE CLUTCH 1 Install Thrust washer D ø34 mm 1 34 in 1 Spacer 2 Bearing 3 Primary driven gear 4 Apply the transmission oil on the bearing spac er and primary driven gear inner circumfer ...

Page 115: ...ates al ternately on the clutch boss starting with a friction plate and ending with a friction plate Apply the transmission oil on the friction plates and clutch plates 6 Install Bearing 1 Washer 2 Circlip 3 To push rod 1 4 Apply the lithium soap base grease on the bearing and washer 7 Install Push rod 2 1 Ball 2 Push rod 1 3 Apply the transmission oil on the push rod 1 2 and ball Nut clutch boss ...

Page 116: ...cross pattern 10 Install Dowel pin 1 Gasket clutch cover 2 11 Install Clutch cover 1 Bolt clutch cover Tighten the bolts in stage using a crisscross pattern 12 Install O ring 1 Clutch cable 2 Apply the lithium soap base grease on the O ring Bolt clutch spring 10 Nm 1 0 m kg 7 2 ft lb Bolt clutch cover 10 Nm 1 0 m kg 7 2 ft lb ...

Page 117: ...the CHAP TER 3 Clutch cable Disconnect at engine side Bolt brake pedal Shift the brake pedal downward Radiator hose 4 Disconnect at water pump side Bolt push rod Refer to CYLINDER HEAD CYLIN DER AND PISTON section 1 Kickstarter crank 1 2 Crankcase cover right 1 3 Bolt Primary drive gear 1 Only loosening Refer to removal section 4 Primary driven gear 1 Refer to CLUTCH section 5 Primary drive gear 1...

Page 118: ... SHIFT SHAFT Order Part name Q ty Remarks 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Shift pedal 1 4 Shift shaft 1 5 Roller 1 6 Shift guide 1 Refer to removal section 7 Shift lever assembly 1 Refer to removal section 8 Stopper lever 1 ...

Page 119: ...EMBLY 1 Remove Bolt shift guide Shift guide 1 Shift lever assembly 2 The shift lever assembly is disassembled at the same time as the shift guide CHECKING THE KICK SHAFT AND KICK GEAR 1 Check Kick gear smooth movement Unsmooth movement Replace 2 Inspect Kick shaft 1 Wear damage Replace CHECKING THE KICK GEAR AND KICK IDLE GEAR 1 Inspect Kick gear 1 Kick idle gear 2 Gear teeth a Wear damage Replace...

Page 120: ...Roller 2 Rotate outer race with a finger Rough spot Seizure Replace the stopper lever Torsion spring 3 Broken Replace CHECKING THE PRIMARY DRIVE GEAR AND PRIMARY DRIVEN GEAR 1 Inspect Primary drive gear 1 Primary driven gear 2 Wear Damage Replace INSTALLING THE STOPPER LEVER 1 Install Torsion spring 1 Stopper lever 2 Bolt stopper lever 3 Align the stopper lever roller with the slot on segment When...

Page 121: ...shift guide 2 3 Install Shift lever assembly 1 Shift guide 2 The shift lever assembly is installed at the same time as the shift guide Apply the transmission oil on the bolt seg ment shaft 4 Install Bolt shift guide 1 INSTALLING THE SHIFT SHAFT 1 Install Roller 1 Shift shaft 2 Apply the transmission oil on the roller and shift shaft Bolt shift guide 10 Nm 1 0 m kg 7 2 ft lb ...

Page 122: ...e spring guide fits on the stopper of the torsion spring 3 Install Kick shaft assembly 1 Apply the transmission oil on the kick shaft Slide the kick shaft assembly into the crank case make sure the clip 2 and kick shaft stopper a fit into their home position b c 4 Hook Torsion spring 1 Turn the torsion spring clockwise and hook into the proper hole a in the crankcase INSTALLING THE KICK IDLE GEAR ...

Page 123: ... drive gear 1 Place an aluminum plate a between the teeth of the primary drive gear and driven gear 4 Install Dowel pin 1 Gasket crankcase cover right 2 5 Install Crankcase cover right 1 Mesh the governor gear 2 and impeller shaft gear 3 with primary drive gear 4 6 Install Bolt crankcase cover right 1 Tighten the bolts in stage using a crisscross pattern Bolt primary drive gear 48 Nm 4 8 m kg 35 f...

Page 124: ...ntact ing the pillar tube 4 8 Install Shift pedal 1 Bolt shift pedal 2 Align the upper line a of the shift pedal with the center b of the crankcase projection and rotate the shift pedal counterclockwise until it first engages Then install the shift pedal Bolt kick starter 10 Nm 1 0 m kg 7 2 ft lb Bolt shift pedal 12 Nm 1 2 m kg 8 7 ft lb ...

Page 125: ... Right crankcase cover Refer to KICK SHAFT AND SHIFT SHAFT section 1 Governor assembly 1 2 Dowel pin 1 Refer to removal section 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Plain washer 4 7 Thrust bearing 2 8 Collar 1 9 Plate 1 10 Compression spring 1 11 Governor gear 1 12 Governor shaft 1 ...

Page 126: ...ce CHECKING THE BEARING 1 Inspect Thrust bearing 1 Washer 2 Wear Damage Replace INSTALLING THE GOVERNOR 1 Install Governor gear 1 Compression spring 2 Plate 3 Washer 4 Thrust bearing 5 Collar 6 Retainer weight 7 To governor shaft 8 Apply the lithium soap base grease on the thrust bearing 2 Install Ball 1 Retainer 2 To governor shaft 3 Apply the transmission oil on the retainer and ball ...

Page 127: ...1 While compressing the spring install the dow el pin Make sure the dowel pin fits into the groove a in the retainer 4 Install Governor assembly 1 Align the groove a in the governor with the fork b and set the governor in the crankcase cover ...

Page 128: ...ame Q ty Remarks Crankcase cover right Refer to KICK SHAFT AND SHIFT SHAFT section 1 Water pump housing cover 1 2 Impeller shaft gear 1 3 Dowel pin 1 4 Plain washer 1 5 Impeller shaft assembly 1 6 Bearing 1 Refer to removal section 7 Oil seal 2 Refer to removal section ...

Page 129: ...shaft 1 Bend wear damage Replace Fur deposits Clean CHECKING THE IMPELLER SHAFT GEAR 1 Inspect Gear teeth a Wear damage Replace CHECKING THE BEARING 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace CHECKING THE OIL SEAL 1 Inspect Oil seal 1 Wear damage Replace INSTALLING THE OIL SEAL 1 Install Oil seal inside 1 Oil seal outside 2 Apply the lithium soap base grease on th...

Page 130: ... oil seal lip and impeller shaft And install the shaft while turning it 2 Install Washer 1 Dowel pin 2 Impeller shaft gear 3 Collar 4 Washer 5 Circlip 6 Install the Impeller shaft gear with the dowel pin fitted in the groove a in the same gear 3 Install Dowel pin 1 Gasket water pump housing cover 2 4 Install Water pump housing cover 1 Bolt water pump housing cover 2 Copper washer coolant drain bol...

Page 131: ...y Remarks Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt Radiator Refer to RADIATOR section Disconnect the CDI magneto lead 1 Left crankcase cover 1 2 Nut rotor 1 Refer to removal section 3 Rotor 1 Refer to removal section 4 Stator 1 5 Woodruff key 1 ...

Page 132: ...GNETO 1 Inspect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator CHECKING THE WOODRUFF KEY 1 Inspect Woodruff key 1 Damage Replace INSTALLING THE CDI MAGNETO 1 Install Stator 1 Screw stator 2 Temporarily tighten the screw stator at this point Rotor holding tool YU 1235 90890 01235 Flywheel puller...

Page 133: ...timing Refer to CHECKING THE IGNITION TIM ING section in the CHAPTER 3 5 Tighten Screw stator 1 6 Check Ignition timing Re check the ignition timing 7 Connect CDI magneto lead 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 8 Install Gasket crankcase cover left Crankcase cover left 1 Screw crankcase cover left 2 Tighten the screws in stage using a crisscross pattern Nut rotor 56 Nm 5 6 m...

Page 134: ...ction Exhaust pipe and silencer Refer to EXHAUST PIPE AND SI LENCER section Clutch cable Disconnect at the engine side Radiator Refer to RADIATOR section Spark plug cap Disconnect the CDI magneto lead 1 Drive chain sprocket cover 1 2 Nut drive sprocket 1 Refer to removal section 3 Lock washer 1 Refer to removal section 26 Nm 2 6 m kg 19 ft lb 64 Nm 6 4 m kg 46 ft lb 64 Nm 6 4 m kg 46 ft lb 85 Nm 8...

Page 135: ...gine bracket 2 9 Engine mounting bolt 3 10 Pivot shaft 1 Refer to removal section 11 Engine 1 Refer to removal section Order Part name Q ty Remarks 26 Nm 2 6 m kg 19 ft lb 64 Nm 6 4 m kg 46 ft lb 64 Nm 6 4 m kg 46 ft lb 85 Nm 8 5 m kg 61 ft lb 75 Nm 7 5 m kg 54 ft lb 5 Nm 0 5 m kg 3 6 ft lb 34 Nm 3 4 m kg 24 ft lb ...

Page 136: ...ert a shaft of similar diameter into the other side of the swingarm to support it 2 Remove Engine 1 From right side Make sure that the couplers hoses and cables are disconnected INSTALLING THE ENGINE 1 Install Engine 1 Install the engine from right side Pivot shaft 2 Engine mounting bolt lower 3 Engine mounting bolt front 4 Engine bracket 5 Bolt engine bracket 6 Engine mounting bolt upper 7 Apply ...

Page 137: ...1 Drive chain 2 Install the drive sprocket together with the drive chain 2 Install Lock washer 1 Nut drive sprocket 2 Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut 4 Install Drive chain sprocket guide 1 Drive chain sprocket cover 2 Screw drive chain sprocket cover 3 Bolt brake pedal 26 Nm 2 6 m kg 19 ft lb Nut drive sprocket 75 Nm 7 5 m kg 54 ft lb Screw ...

Page 138: ... gear Refer to KICK SHAFT AND SHIFT SHAFT section Kick idle gear Refer to KICK SHAFT AND SHIFT SHAFT section Stopper lever Refer to KICK SHAFT AND SHIFT SHAFT section Rotor and stator Refer to CDI MAGNETO section 1 Segment 1 Refer to removal section 2 Bolt L 45 mm 1 77 in 6 3 Bolt L 55 mm 2 17 in 4 4 Bolt L 65 mm 2 56 in 1 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 2 ft lb 20 Nm 2 0 m kg 14 ft lb 14...

Page 139: ... Refer to removal section 8 Crankcase left 1 Refer to removal section 9 Crankshaft 1 Refer to removal section 10 Oil seal 2 11 Bearing 2 Refer to removal section Order Part name Q ty Remarks 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 2 ft lb 20 Nm 2 0 m kg 14 ft lb 14 Nm 1 4 m kg 10 ft lb ...

Page 140: ...tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw re align and start over If the cases do not sep arate check for a remaining case bolt or fitting Do not force REMOVING THE CRANKSHAFT 1 Remove Crankshaft 1 Use the crankcase separati...

Page 141: ...ge Replace CHECKING THE CRANKSHAFT 1 Measure Runout limit a Small end free play limit b Connecting rod big end side clearance c Crank width d Out of specification Replace Use the dial gauge and a thickness gauge Dial gauge and stand YU 3097 90890 01252 Standard Limit Runout lim it 0 03 mm 0 0012 in 0 05 mm 0 002 in Small end free play 0 8 1 0 mm 0 031 0 039 in 2 0 mm 0 08 in Side clear ance 0 06 0...

Page 142: ... 3 4 Hold the connecting rod at top dead center with one hand while turning the nut of the in stalling tool with the other Operate the install ing tool until the crankshaft bottoms against the bearing Before installing the crankshaft clean the contacting surface of crankcase Apply molybdenum disulfide grease to the surface a where the crankshaft and bearing come in contact Apply the lithium soap b...

Page 143: ...he crankshaft and bearing come in contact Use two plain washers Yamaha genuine 90201 243K3 5 or the ones of a size as shown one on the other Except for USA and CDN Install so that the plain washers do not deviate from the crankshaft center Except for USA and CDN When installing the crankcase the connecting rod should be positioned at TDC top dead center Install while checking that the dowel pin is...

Page 144: ...f the segment gets an impact it may be damaged Take care not to give an impact to the segment when tightening the bolt 9 Remove Sealant Forced out on the cylinder mating surface 10 Apply Engine oil To the crank pin bearing oil delivery hole and connecting rod big end washer 11 Check Crankshaft and transmission operation Unsmooth operation Repair If the crankshaft will not turn smoothly make an adj...

Page 145: ...emarks Engine Refer to ENGINE REMOVAL sec tion Separate the crankcase Refer to CRANKCASE AND CRANKSHAFT section 1 Guide bar long 1 2 Guide bar short 1 3 Shift cam 1 4 Shift fork 3 1 5 Shift fork 1 1 6 Shift fork 2 1 7 Main axle 1 Refer to removal section 8 Drive axle 1 Refer to removal section 9 Collar 1 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 146: ...the lo cation and direction of shift forks CHECKING THE GEARS 1 Inspect Matching dog a Gear teeth b Shift fork groove c Wear damage Replace 2 Check Gears movement Unsmooth movement Repair or replace CHECKING THE BEARING 1 Inspect Bearing 1 Rotate inner race with a finger Rough spot seizure Replace CHECKING THE SHIFT FORK SHIFT CAM AND SEGMENT 1 Inspect Shift fork 1 Wear damage scratches Replace 2 ...

Page 147: ...d end surface of the idler gear and on the in ner surface of the sliding gear then install 2 Install 2nd wheel gear 29T 1 5th wheel gear 24T 2 3rd wheel gear 27T 3 4th wheel gear 23T 4 6th wheel gear 23T 5 1st wheel gear 31T 6 To drive axle 7 Apply the molybdenum disulfide oil on the in ner and end surface of the idler gear and on the inner surface of the sliding gear then in stall Apply the molyb...

Page 148: ...the crankcase oil seal lip 5 Install Main axle 1 Drive axle 2 Apply the transmission oil on the crankcase bearing INSTALLING THE SHIFT CAM AND SHIFT FORK 1 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Mesh the shift fork 1 L with the 5th wheel gear 4 and 3 R with the 6th wheel gear 6 on the drive axle Mesh the shift fork 2 C with the 3rd 4th pin ion gear 5 on the main axle ...

Page 149: ...g up the 5th wheel gear 2 and keeping the shift fork 1 3 moved in the direction of the arrow 3 Install Guide bar short 1 Guide bar long 2 Apply the transmission oil on the guide bars Be sure the long bar is inserted into the shift forks 1 and 3 and the short one into 2 4 Check Shifter operation Transmission operation Unsmooth operation Repair ...

Page 150: ...vicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ...

Page 151: ...r Part name Q ty Remarks Hold the machine by placing the suit able stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 Refer to removal section 8 Brake disc 1 5 ...

Page 152: ...chine by placing the suit able stand under the engine Refer to HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to removal section 10 Brake disc 1 ...

Page 153: ...ING THE WHEEL 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace Replace the bearings oil seal and wheel collar as a set CHECKING THE WHEEL AXLE 1 Measure Wheel axle bends Out of specification Replace Use the dial gauge 1 The bending value is shown by one half of the dial gauge reading Do not attempt to straighten a bent ...

Page 154: ...ing and oil seal lip when installing Use a socket that matches the outside diam eter of the race of the bearing Left side of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward 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 Tighten the bolts in stage using ...

Page 155: ... brake disc 1 between the brake pads 2 correctly 5 Install Wheel axle 1 Apply the lithium soap base grease on the wheel axle 6 Install Nut wheel axle 1 7 Tighten Bolt axle holder 1 Before tightening the bolt fit the wheel axle to the axle holder by stroking the front fork several times with the front brake applied Nut wheel axle 105 Nm 10 5 m kg 75 ft lb Bolt axle holder 21 Nm 2 1 m kg 15 ft lb ...

Page 156: ...l the oil seal with its manufacture s marks or numbers facing outward 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 Tighten the bolts in stage using a crisscross pattern 3 Install Rear wheel sprocket 1 Bolt rear wheel sprocket 2 Washer rear wheel sprocket 3 Nut rear wheel sprocket 4 Tighten the nuts in stage usi...

Page 157: ...n puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 8 Install Right drive chain puller 1 Washer 2 Nut wheel axle 3 Temporarily tighten the nut wheel axle at this point 9 Adjust Drive chain slack a Refer to ADJUSTING THE DRIVE CHAIN SLACK section in the CHAPTER 3 10 Tighten Nut wheel axle 1 Locknut 2 Drive chain slack 48 58 mm 1 9 2 3 in Nut wheel ...

Page 158: ...stand under the engine Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Union bolt 2 3 Brake hose 1 4 Pad pin plug 1 Remove when loosening the pad pin 5 Pad pin 1 Loosen when disassembling the brake caliper 6 Brake caliper 1 7 Brake lever 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 ...

Page 159: ...ine Refer to HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake 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 brake caliper 8 Brake caliper 1 ...

Page 160: ...Order Part name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal section 6 Brake caliper piston seal 2 1 Refer to removal section ...

Page 161: ...LINDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Push rod Front 1 5 Brake master cylinder boot 1 6 Circlip 1 Use a long nose circlip pliers 7 Washer 1 8 Push rod Rear 1 9 Brake master cylinder kit 1 ...

Page 162: ...while pulling the lever in or pushing down on the pedal Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately REMOVING THE BRAKE CALIPER PISTON 1 Remove Brake caliper piston Use compressed air and proceed carefully Cover piston with rag and use extreme caution when expelling piston from cylin der Never attempt to pry ...

Page 163: ... the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled A Front B Rear CHECKING THE BRAKE MASTER CYLINDER 1 Inspect Brake master cylinder inner surface a Wear scratches Replace master cylinder assembly Stains Clean Use only new brake fluid A Front B Rear 2 Inspect Diaphragm 1 Crack damage Replace A Front B Rear 3 Inspect front brake only Reservoir flo...

Page 164: ...ernal parts should be lubricated with brake fluid when installed Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled INSTALLING THE BRAKE CALIPER PISTON 1 Clean Brake caliper Brake caliper piston seal Brake caliper piston dust seal Brake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper piston du...

Page 165: ...e brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point 2 Install Brake caliper 1 Bolt brake caliper 2 3 Tighten Pad pin 3 4 Install Pad pin plug 4 INSTALLING THE REAR BRAKE CALIPER 1 Install Pad support 1 Brake pad 2 Pad pin 3 Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad ...

Page 166: ...ith brake fluid 2 Install Brake master cylinder cup primary 1 Brake master cylinder cup secondary 2 To brake master cylinder piston 3 Apply the brake fluid on the brake master cylin der cup After installing cylinder cup should be in stalled as shown direction Wrong installa tion cause improper brake performance 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller ...

Page 167: ...ONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder bracket 2 Bolt brake master cylinder bracket 3 Install the bracket so that the arrow mark a face upward First tighten the bolts on the upper side of the brake master cylinder bracket and then tight en the bolts on the lower side 2 Install Brake lever 1 Bolt brake lever 2 Nut brake lever 3 Apply the silicone grease on...

Page 168: ...linder 2 Install Brake master cylinder 1 Bolt brake master cylinder 2 3 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 Apply the lithium soap base grease on the bolt O ring and brake pedal bracket 4 Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to ADJUSTING THE REAR BRAKE section in the CHAPTER 3 Union bolt 30 Nm 3 0 m kg 22 ft lb Bolt b...

Page 169: ...e holder 1 Bolt brake hose holder 2 Align the top a of the brake hose holder with the paint b of the brake hose 3 Pass the brake hose through the cable guide 1 4 Install Copper washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe por tion a directs as shown and lightly touch es the projection b on the brake master cylinder Union bolt 30 Nm 3 0 m ...

Page 170: ...oes correct its twist FILLING THE BRAKE FLUID 1 Fill Brake fluid Until the fluid level reaches LOWER level line a Use only the designated quality brake flu id otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance Be careful that water does...

Page 171: ...ction in the CHAPTER 3 4 Install Reservoir float front brake Diaphragm Brake master cylinder cap 1 Screw bolt brake master cylinder cap 2 After installation while pulling the brake le ver in or pushing down on the brake pedal check whether there is any brake fluid leak ing where the union bolts are installed re spectively at the brake master cylinder and brake caliper A Front B Rear 5 Install rear...

Page 172: ...er to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 1 Protector 1 2 Pinch bolt upper bracket 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Refer to removal section 4 Pinch bolt lower bracket 2 Only loosening 5 Front fork 1 ...

Page 173: ...ring 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 10 Oil seal 1 11 Base valve 1 Drain the fork oil Refer to removal section 12 Damper assembly 1 Drain the fork oil Refer to removal section 30 Nm 3 0 m kg 22 ft lb 29 Nm 2 9 m kg 21 ft lb 29 Nm 2 9 m kg 21 ft lb 1 Nm 0 1 m kg 0 7 ft lb 55 Nm 5 5 m kg 40 ft lb ...

Page 174: ...es or front forks be sure to extract the air from the air chamber completely REMOVING THE DAMPER ASSEMBLY 1 Loosen Damper assembly 1 Before removing the front fork from the ma chine loosen the damper assembly with the cap bolt ring wrench 2 REMOVING THE ADJUSTER 1 Drain the outer tube of its front fork oil at its top 2 Loosen Adjuster 1 3 Remove Adjuster 1 While compressing the inner tube 2 set th...

Page 175: ...mper assembly 1 Bend damage Replace O ring 2 Wear damage Replace The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign mate rial 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 CHECKING THE BASE VALVE 1 Inspect Base valve 1 Wear da...

Page 176: ... oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge 1 The bending value is shown by one half of the dial gauge reading Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube CHECKING THE OUTER TUBE 1 Inspect Outer tube 1 Score marks wear damage Replace CHECKING THE ADJUSTER 1 Inspect Adjuster 1 O ring 2 Wear damage Replace Fork s...

Page 177: ...pump the damper assembly 1 slowly up and down about 200 mm 7 9 in stroke several times to bleed the damper assembly of air Be careful not to excessive full stroke A stroke of 200 mm 7 9 in or more will cause air to en ter In this case repeat the steps 2 to 4 5 Measure Oil level left and right a Out of specification Adjust 6 Tighten Locknut 1 Fully finger tighten the locknut onto the damper assembl...

Page 178: ...fully stretched Repeat the steps 2 to 8 10 Tighten Base valve 1 Hold the damper assembly with the cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve with specified torque 11 After filling pump the damper assembly 1 slowly up and down more than 10 times to distribute the fork oil 12 While protecting the damper assembly 1 with a rag and compressing fully allow ex cessive ...

Page 179: ...Stopper ring 2 Oil seal 3 Oil seal washer 4 Slide metal 5 To inner tube 6 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 16 Install Piston metal 1 Install the piston metal onto the slot on inner tube 17 Install Outer tube 1 To...

Page 180: ...seal into the outer tube with fork seal driver 2 20 Install Stopper ring 1 Fit the stopper ring correctly in the groove in the outer tube 21 Install Dust seal 1 Apply the lithium soap base grease on the inner tube 22 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 15 to 21 Fork seal driver YM A0948 90890 01502 Fork seal driver YM A0948 90890 01502 ...

Page 181: ...may fall into it damaging the valve inside 26 Loosen Rebound damping adjuster 1 Loosen the rebound damping adjuster finger tight Record the set position of the adjuster the amount of turning out the fully turned in posi tion 27 Install Push rod 1 Copper washer 2 Adjuster 3 To damper assembly 4 While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fu...

Page 182: ...m and minimum amount and always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Be sure to use recommended fork oil If other oils are used they may have an ex cessively adverse effect on the front fork performance Never allow foreign materials to enter the front fork Gap a between the adjuster and locknut 0 5 1 0 mm 0 02 0 04 in Adjuster l...

Page 183: ...fork 1 Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts upper bracket yet 2 Tighten Damper assembly 1 Use the cap bolt ring wrench 2 to tighten the damper assembly with specified torque 3 Adjust Front fork top end a Damper assembly 30 Nm 3 0 m kg 22 ft lb Cap bolt ring wrench YM 01501 90890 01501 Front fork top end standard a 5 mm 0 20 in ...

Page 184: ...r 1 Bolt protector 2 6 Adjust Rebound damping force Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Pinch bolt upper bracket 21 Nm 2 1 m kg 15 ft lb Pinch bolt lower bracket 21 Nm 2 1 m kg 15 ft lb Bolt protector 5 Nm 0 5 m kg ...

Page 185: ...oval section 5 Throttle cable cap 1 Turn over the cap cover 6 Throttle cable 1 Disconnect at the throttle side 7 Throttle 1 Loosen the bolts 8 Cap cover 1 9 Collar 1 10 Left grip 1 Refer to removal section 11 Handlebar upper holder 2 12 Handlebar 1 13 Handlebar lower holder 2 1 Nm 0 1 m kg 0 7 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 9 Nm 0 9 m kg 6 5 ft lb 28 ...

Page 186: ...5 37 HANDLEBAR DISASSEMBLING THE THROTTLE Order Part name Q ty Remarks 1 Grip cap lower 1 2 Grip cap upper 1 3 Grip assembly 1 4 Grip right 1 Refer to removal section 5 Tube guide 1 ...

Page 187: ...he handlebar or tube guide and the grip Then remove the grip which has become loose CHECKING THE HANDLEBAR 1 Inspect Handlebar 1 Bends cracks damage Replace Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar ASSEMBLING THE THROTTLE 1 Remove Grip right 1 Apply the adhesive on the tube guide 2 Before applying the adhesive wipe off grease or oil on the tube gu...

Page 188: ...in the re verse direction allows the front to rear offset amount of the handlebar position to be changed Do not tighten the nut yet 2 Install Handlebar 1 Handlebar upper holder 2 Bolt handlebar upper holder 3 The handlebar upper holder should be in stalled with the punched mark a forward Install the handlebar so that the marks b are in place on both sides Install the handlebar so that the projecti...

Page 189: ...the line b between the two arrow marks faces straight upward 5 Install Collar 1 Grip cap cover 2 Throttle grip 3 Apply the lithium soap base grease on the throttle grip sliding surface Tighten the grip cap bolts temporarily without the throttle being fixed to the handlebar 6 Install Throttle cables 1 To tube guide 2 Apply the lithium soap base grease on the throttle cable end and tube guide cable ...

Page 190: ...0 Install Cap cover 1 11 Install Brake master cylinder 1 Brake master cylinder bracket 2 Bolt brake master cylinder bracket 3 Install the bracket so that the arrow mark a faces upward First tighten the bolt on the upper side of the brake master cylinder bracket and then tight en the bolt on the lower side 12 Install Bolt grip cap 1 After tightening the bolts check that the throttle grip 2 moves sm...

Page 191: ...e installed according to the dimensions shown Pass the engine stop switch lead in the middle of the clutch lever holder 14 Install Clutch cable 1 Apply the lithium soap base grease on the clutch cable end 15 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH CA BLE FREE PLAY section in the CHAPTER 3 Bolt clutch lever holder 4 Nm 0 4 m kg 2 9 ft lb 0 55 in ...

Page 192: ...one turn Retighten it 7 Nm 0 7 m kg 5 1 ft lb Hold the machine by placing the suit able stand under the engine Refer to HANDLING NOTE Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Handlebar Refer to HANDLEBAR section Front fender 1 Steering stem nut 1 2 Front fork 2 Refer to FRONT FORK section 3 Upper bracket 1 ...

Page 193: ...Steering ring nut 1 Refer to removal section 5 Lower bracket 1 6 Bearing race cover 1 7 Upper bearing 1 8 Lower bearing 1 Refer to removal section 9 Bearing race 2 Refer to removal section Order Part name Q ty Remarks ...

Page 194: ...BEARING RACE 1 Remove Bearing race 1 Remove the bearing race using long rod 2 and the hammer CHECKING THE STEERING STEM 1 Inspect Steering stem 1 Bend damage Replace CHECKING THE BEARING AND BEARING RACE 1 Wash the bearings and bearing races with a solvent 2 Inspect Bearing 1 Bearing race Pitting damage Replace bearings and bearing races as a set Install the bearing in the bearing races Spin the b...

Page 195: ...3 Install Lower bracket 1 Apply the lithium soap base grease on the bearing the portion a and thread of the steer ing stem 4 Install Steering ring nut 1 Tighten the steering ring nut using the steer ing nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD section in the CHAPTER 3 5 Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembl...

Page 196: ...t adjust the steering by loosening the steering ring nut little by little 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Steering stem nut 145 Nm 14 5 m kg 105 ft lb Front fork top end standard a 5 mm 0 20 in Pinch bolt upper bracket 21 Nm 2 ...

Page 197: ...LING NOTE Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive chain support 1 2 Lower chain tensioner 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 ...

Page 198: ...s 1 Cap 2 Refer to removal section 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bushing 2 8 Oil seal 8 9 Bearing 10 Refer to removal section 70 Nm 7 0 m kg 50 ft lb 80 Nm 8 0 m kg 58 ft lb 2 Nm 0 2 m kg 1 4 ft lb 6 Nm 0 6 m kg 4 3 ft lb ...

Page 199: ... CHECKING THE SWINGARM 1 Inspect Bearing 1 Bushing 2 Free play exists unsmooth revolution rust Replace bearing and bushing as a set 2 Inspect Oil seal 3 Damage Replace CHECKING THE RELAY ARM 1 Inspect Bearing 1 Collar 2 Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect Oil seal 3 Damage Replace CHECKING THE CONNECTING ROD 1 Inspect Bearing 1 Collar 2 Free play...

Page 200: ...arm Apply the molybdenum disulfide grease on the bearing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers Apply the molybdenum disulfide grease on the washer 3 Install Bearing 1 Oil seal 2 To connecting rod Apply the molybdenum disulfide grease on the bearing when installing Install the bearing by pressing it on the side having the manufactur...

Page 201: ...grease on the collars and oil seal lips 3 Install Collar 1 To connecting rod 2 Apply the molybdenum disulfide grease on the collar and oil seal lips 4 Install Connecting rod 1 Bolt connecting rod 2 Washer 3 Nut connecting rod 4 To relay arm 5 Apply the molybdenum disulfide grease on the bolt 5 Install Relay arm 1 Bolt relay arm 2 Washer 3 Nut relay arm 4 To swingarm Apply the molybdenum disulfide ...

Page 202: ...rease or replace bearings bushings and collars 8 Install Bolt connecting rod 1 Washer 2 Nut connecting rod 3 Apply the molybdenum disulfide grease on the bolt Do not tighten the nut yet 9 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 Apply the molybdenum disulfide grease on the bolt 10 Tighten Nut connecting rod 1 Pivot shaft 85 Nm 8 5 m kg 61 ft lb Nut rear shoc...

Page 203: ...ut lower chain tensioner 5 14 Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut relay arm 70 Nm 7 0 m kg 50 ft lb Nut lower chain tensioner 16 Nm 1 6 m kg 11 ft lb Nut drive chain support 7 Nm 0 7 m kg 5 1 ft lb Bolt drive chain support cover 7 Nm 0 7 m kg 5 1 ft lb ...

Page 204: ...section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SI LENCER section in the CHAPTER 4 1 Clamp air filter joint 1 Only loosening 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 Only loosening 7 Adjuster 1 Only loosening 53 Nm 5 3 m kg 38 ft lb 56 Nm 5 6 m kg 40 ft lb 2 Nm 0 2 m kg 1 4 ft lb 32 Nm...

Page 205: ...ing guide 1 10 Upper spring guide 1 11 Spring rear shock absorber 1 12 Bearing 2 Refer to removal section Order Part name Q ty Remarks 53 Nm 5 3 m kg 38 ft lb 56 Nm 5 6 m kg 40 ft lb 2 Nm 0 2 m kg 1 4 ft lb 32 Nm 3 2 m kg 23 ft lb 29 Nm 2 9 m kg 21 ft lb ...

Page 206: ...rt of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug When scrapping the rear shock absorb er follow the instructions on disposal NOTES ON DI...

Page 207: ...spring up and down Spring guide 4 Wear damage Replace spring guide Spring seat 5 Cracks damage Replace Bearing 6 Free play exists unsmooth revolution rust Replace INSTALLING THE BEARING 1 Install Upper bearing 1 Install the bearing parallel until the stopper ring groove appears by pressing its outer race Do not apply the grease on the bearing out er race because it will wear the rear shock absorbe...

Page 208: ...pring seat with the projection a brought into contact with the spring end as shown 3 Tighten Adjuster 1 4 Adjust Spring length installed Refer to ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD section in the CHAPTER 3 5 Tighten Locknut 1 INSTALLING THE REAR SHOCK ABSORBER 1 Install Dust seal 1 O ring 2 Collar 3 Apply the molybdenum disulfide grease on the dust seal lips and collars Apply the lit...

Page 209: ...bdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 Apply the molybdenum disulfide grease on the bolt 6 Install Rear frame 1 Bolt rear frame upper 2 Bolt rear frame lower 3 7 Tighten Bolt air filter joint 1 Nut rear shock absorber frame 56 Nm 5 6 m kg 40 ft lb Nut rear shock absorber relay arm 53 Nm 5 3 m kg 38 ft lb Bolt rear fram...

Page 210: ...ervicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ...

Page 211: ...6 2 ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1 Engine stop switch 2 CDI unit 3 Ignition coil 4 CDI magneto 5 Spark plug 6 ...

Page 212: ...WIRING DIAGRAM WIRING DIAGRAM 1 Engine stop switch 2 CDI unit 3 Ignition coil 4 CDI magneto 5 Spark plug COLOR CODE B Black O Orange Y Yellow B R Black Red B W Black White G L Green Blue G W Green White W L White Blue W R White Red ...

Page 213: ...at 2 Fuel tank Use the following special tools in this inspection Spark gap test Spark Clean or replace spark plug No spark Check entire ignition system for connec tion No good Repair or replace OK Check engine stop switch No good Replace OK Check ignition coil primary coil and secondary coil No good Replace OK Check spark plug cap No good Replace OK Check CDI magneto pickup coil and charging coil...

Page 214: ...leads connection Rust dust looseness short circuit Repair or replace CHECKING THE ENGINE STOP SWITCH 1 Inspect Engine stop switch conduction Not conductive while it is pushed Replace Conductive while it is freed Replace Set the tester selection position to Ω 1 CHECKING THE IGNITION COIL 1 Inspect Primary coil resistance Out of specification Replace Minimum spark gap 6 0 mm 0 24 in Tester lead Blac...

Page 215: ... specification Replace 2 Inspect Charging coil 1 resistance Out of specification Replace Tester lead Spark plug lead 1 Tester lead Yellow lead 2 Secondary coil resistance Tester selector position 5 7 8 5 kΩat 20 C 68 F kΩ 1 Tester lead Spark plug lead terminal 1 Tester lead Spark plug terminal 2 Spark plug cap resistance Tester selector position 4 6 kΩ at 20 C 68 F kΩ 1 Tester lead White Red lead ...

Page 216: ...Replace CHECKING THE CDI UNIT Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again Tester lead Green Blue lead 1 Tester lead Black lead 2 Charging coil 2 resistance Tester selector position 44 66 Ω at 20 C 68 F Ω 10 ...

Page 217: ...s It is advisable to make a note of settings atmo spheric conditions road surface condition lap time etc so that the memorandum can be used as a reference useful for future ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS The reason for the above tendency is that the richness or leanness of a fuel mixture depends on the density of the air i e the concentration of oxygen in it Higher temperature expa...

Page 218: ...g lower calibrating No than standard To be leaned out ADJUSTING THE PILOT AIR SCREW The richness of the air fuel mixture with full closed to 1 4 throttle can be set by turning the pilot air screw 1 Turning in the pilot air screw will enrich the mixture at low speeds and turn ing out it will lean out the mixture ADJUSTING THE PILOT JET The richness of air fuel mixture with the throttle fully closed...

Page 219: ...etting parts having the same taper angle are available in different straight portion diameters and in different taper starting positions In the case of the same number of clip position changing from 6BFY42 74 to 6BFY43 74 has the same effect as a rising of 0 5 clip position And in the case of the same number of clip po sition changing from 6BFY42 74 to 6BFY44 74 has the same effect as a rising of ...

Page 220: ...8 throttle to the 1st tapered portion at 1 4 throttle to the second tapered portion at 1 2 throttle to the third tapered portion at 3 4 throttle and to the fourth tapered portion at full open Therefore the fuel flow is balanced at each stage of throttle opening by a combination of the jet needle diameter and clip position Example For USA and CDN For EUROPE AUS NZ and ZA A Lean larger diameter B Ri...

Page 221: ...35 32 5 4KM 14142 32 Lean 30 4KM 14142 30 Throttle valve 3 Rich STD 4 0 1C3 14112 40 4 25 1C3 14112 42 Lean Jet needle 4 Rich 6BFY44 72 284 14116 K2 6BFY44 73 284 14116 K3 6BFY44 74 284 14116 K4 6BFY44 75 284 14116 K5 Lean 6BFY44 76 284 14116 K6 Rich 6BFY43 72 284 14116 J2 6BFY43 73 284 14116 J3 STD 6BFY43 74 284 14116 J4 6BFY43 75 284 14116 J5 Lean 6BFY43 76 284 14116 J6 Rich 6BFY42 72 284 14116 ...

Page 222: ...er 6BFY44 72 3 6BFY44 73 3 6BFY44 74 3 6BFY44 75 3 6BFY44 76 3 6BFY42 72 4 6BFY42 73 4 6BFY42 74 4 6BFY42 75 4 6BFY42 76 4 0 5 richer 6BFY43 72 3 6BFY43 73 3 6BFY43 74 3 6BFY43 75 3 6BFY43 76 3 STD 6BFY42 72 3 6BFY42 73 3 6BFY42 74 3 6BFY42 75 3 6BFY42 76 3 0 5 leaner 6BFY43 72 2 6BFY43 73 2 6BFY43 74 2 6BFY43 75 2 6BFY43 76 2 1 leaner 6BFY44 72 1 6BFY44 73 1 6BFY44 74 1 6BFY44 75 1 6BFY44 76 1 Le...

Page 223: ...d from the top If a change in the clip position 1 groove is effective try another jet needle that provides a difference of 0 5 in the clip position 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 White smoke Poor acceleration Raise jet needle clip position 1 groove...

Page 224: ... screw If the result of setting is still unsatisfactory it is advisable to change the diameter of the straight portion the jet needle Poor response when throttle is opened quickly Check overall settings Use main jet having lower calibra tion no Raise jet needle clip position 1 groove up If no effect reverse the above pro cedures Check air filter for fouling Poor engine operation Turn in pilot air ...

Page 225: ...of the main jet must be changed by 30 it is advisable to change the heat range of spark plugs and newly select the proper main jet When checking the discoloration of spark plugs be sure to stop the engine immediately after a run and check Avoid racing When changing the heat range of spark plugs never attempt to change it more than 1 rank When using a spark plug other than standard check its heat r...

Page 226: ...speed the ma chine is generally set such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the level ...

Page 227: ...l cause the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteris tics Therefore adjust the front fork within the specified range A Air spring characteristics in relation to oil amount change B Load C Stroke 1 Max oil amount 2 Standard oil amount 3 Min oil amount SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be ...

Page 228: ...ing Change the compression damping CHOOSING SET LENGTH 1 Place a stand or block under the engine to put the rear wheel above the floor and mea sure 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 hold ing b...

Page 229: ...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 damp ing to compensate for its greater spring load Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be foll...

Page 230: ...the CHAPTER 3 Preload adjusting extent is the same for the ti tanium and steel springs TYPE SPRING RATE SPRING PART NUMBER 22212 I D MARK Green 1 SOFT 4 5 1C3 00 Green 2 Green 3 Red 1 STD 4 7 1C3 10 Red 2 Red 3 STIFF Black 1 4 9 1C3 20 Black 2 Black 3 Blue 1 5 1 1C3 30 Blue 2 Blue 3 TYPE SPRING RATE SPRING PART NUMBER 22212 I D MARK Q TY SOFT 4 3 5UN 00 Brown 1 5 3 5UN 50 Yellow 1 STIFF 5 5 5UN 60...

Page 231: ...ntire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to in crease damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Replace with stiff spring Stiff toward stroke end Oil amount Decrease oil amount by about 5 cm3 0 2 Imp oz 0 2 US oz Soft toward stroke end bottoming out Oil amount Increase oil amount by about 5 cm3 0 2 Imp o...

Page 232: ...Heavy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression damping Turn adjuster clockwise about 1 clicks to in crease damping High compression damping Turn adjuster clockwise about 1 6 turn to in crease dampi...

Page 233: ......

Page 234: ...PRINTED IN JAPAN 2008 4 0 4 1 E YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAPER PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories ...

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